Re: 84 4ksq fuel lines & CIS?

[Ragnampiza@aol.com]

In a message dated 8/29/99 11:29:05 PM, AdamB@net1plus.com wrote:

<<Also, the fuel lines are very rusty.  Has anyone replaced these
themselves?  How difficult of a job is it?  Where can one buy fuel lines
for this type of car and do they just fit right in?  Any info and help
would be greatly appreciated.>>

I just did this last week....it was difficult and time consuming

I used four 72" X 5/16" brake lines with unions in the middle....I used the 
stock
fittings  for the ends..they fit well on 5/16" tubing....The stock tubing 
uses reverse flare ends....I called audi for the stock tubing($$$)...which 
was available, but the fittings were not....it comes in a roll and would have 
to be bent also....I decided to save time & $ and used domestic brake 
line.....I've bought cars that had been spliced with high pressure flex line 
but they've always seemed to leak and cause starting problems....

here's the drill:

Use a sharp exacto to cut line @ backside of fuel pump as close as possible 
to inlet (be very careful here as not to cause any sparks)

Drain fuel into (several)gas cans( a big funnel helps here as fuel sprays 
everywhere)

Use tin snips to cut line from fuel filter(Once again being extremely careful 
as not to cause sparks)fuel will spray from high pressure...do this step only 
if you cannot 
undo fitting from filter...If you 've got rust, it probably wont give and 
you're going 
to need to save that fitting,

Once system is clear of fuel....disasemble fuel pump, filter , distributor,& 
bracket assembly
(you my need some kind of cut off tool here as the suspension bushing nuts 
are usually rusted solid to their mounts)

take assembly to benchvise and remove and inspect all fittings very carefully

undo clips and remove remaining fuel line(If your lines are not rusty where 
they
make a turn up under the chassis by the exaust manifold toward the battery 
tray
you may want to make a clean cut there and splice with a 5/16" 
union...because it was very difficult to undo clips and make bends up under 
the battery tray(I had to leave 2 clips unclipped)

replacement:
If you are going for complete replacement of lines..youre first going to need 
to get that car as high off the ground as possible

by bending a tang up in the middle of the battery tray I was able to feed the 
72" brake line through the clip behind the EM heat shield and make my bends

using a good quality flaring tool to make double flares... I slipped on the 
factory fitting and attached the line to the fitting on the SS braided hose 
by cranking the shit out of it (the Factory lines use reverse flares here...I 
dont have a reverse flair tool, but they are available from Summit....I made 
it work with standard flairs by cranking on it ...HARD....no leaks

Use the domestic 5/16" unions to connect your second 72" tube under the car 

I dissemled the fittings from the fuel filter by cranking on it in the 
benchvise
Liquid wrench helps immencely

I sand blasted everything (pump, distibutor, mounts) used a conversion coat 
to nuetralize remaining rust & applied rustoleum

always use fresh filter

the hardest bend is the last one entering the filter.....crank hard

I used new high pressure flex lines and clips to replace the factory shrink 
lines from the distibutor.....

and set everything else up on brand new suspension bushings

removal of exaust from behind the manifold eases this entire task

total cost ...around $75....depending on how cheap you get the filter

cost to have a shop do it....Outrageous