Fuel Line Maintenance: Replacing Vital Lines On 944 Turbos

The Porsche 944 is a classic car, but like any ageing vehicle, it has its issues. One common problem is the fuel lines, which tend to crack and leak over time. Owners have a few options when it comes to replacement, including using modern PTFE lines, braided lines, or even building their own with 6AN fittings and hoses. While it is possible to replace the lines yourself, it is important to take precautions when working with fuel, as it is highly combustible.

Replacing rubber hoses with braided lines

Braided hoses are a great replacement for rubber hoses in plumbing and car engines. They are safer, more durable, and more rigid than their rubber counterparts. This article will focus on the benefits of braided hoses and how to replace rubber hoses with braided lines in Porsche 944 Turbos.

Benefits of Braided Hoses

Braided hoses, typically made of steel, offer several advantages over rubber hoses:

• Longevity: Braided steel hoses last longer than rubber hoses, which are sensitive to heat, water, and chemicals. Rubber hoses are susceptible to leaks or bursts, which can lead to flooding and water damage. Braided steel hoses are tougher and can withstand higher water pressure and more wear and tear.
• Safety: The reduced likelihood of bursting in steel hoses means there is a lower risk of water damage to your home and a reduced chance of dealing with electrical hazards and slippery surfaces that could cause accidents.
• Rigidity: Braided steel hoses do not bend, ensuring uninterrupted water flow and optimal performance of appliances such as washing machines and dishwashers. Rubber hoses, being easily bendable, can hamper water flow and the efficiency of appliances.

Now, let's discuss the process of replacing rubber fuel lines with braided lines in a Porsche 944 Turbo:

• You can purchase braided fuel lines from various sources, such as Lindsey Racing, Lartsporscheparts on eBay, or local hydraulic specialists.
• Some Porsche 944 owners have recommended using nylon stainless steel braided lines, which can be more durable and cost-effective.
• When replacing the fuel lines, you may need to adapt the fittings to match the braided lines. For example, using -6AN fittings and hoses or adapting between -6AN and Push-Lock.
• If you are comfortable with the existing rubber hose routing, you can simply replace the rubber hoses with braided lines using appropriate clamps and fittings.
• For a more comprehensive upgrade, you can reroute the fuel lines to avoid the exhaust manifold, providing additional safety.
• It is recommended to consult a qualified specialist or mechanic for advice and assistance during this process, especially if you are unsure about any steps.

In conclusion, replacing rubber hoses with braided lines offers improved durability, safety, and performance. Braided steel hoses are a worthwhile investment to protect your car and your home from potential damage caused by leaking or bursting rubber hoses.

Using Cuprol Nickle Fuel line

Cuprol Nickel fuel line is a popular choice for car enthusiasts when replacing fuel lines. It is a durable and flexible option that is designed to meet high standards of quality and performance. One of the key benefits of Cuprol Nickel fuel line is its resistance to rust and corrosion, making it a long-lasting solution for your vehicle.

Cuprol Nickel fuel line is available in a variety of sizes and lengths to accommodate different project requirements. It can be purchased in coils or straight lines, depending on your specific needs. The tubing is typically sold in lengths ranging from 20" to 200', ensuring you have enough material for your fuel line replacement.

When using Cuprol Nickel fuel line for your 944 Turbo, you will need to purchase additional fittings and tools. This includes fittings to connect the fuel line to the appropriate compression fittings and a tool for moulding the ends, similar to a copper brake line. You may also need to purchase fittings for any joins that connect to a compression fitting.

The Cuprol Nickel fuel line is known for its ease of use and bending capabilities. It can be bent and flared with ease, making it a popular choice for those looking for a straightforward installation process. Additionally, its flexibility allows for easy handling and specific routing requirements.

When considering Cuprol Nickel fuel line for your 944 Turbo, it is important to source the tubing from reputable suppliers to ensure the highest quality. While it may be available on eBay or other online platforms, it is recommended to research and compare different options to find the best product for your vehicle.

Replacing banjo bolt with -6AN fitting

When replacing the banjo bolt with a -6AN fitting, it is important to ensure that you have the correct fittings and adapters for the specific fuel lines and hardlines in your vehicle. Here is a step-by-step guide on how to replace the banjo bolt with a -6AN fitting on a 944 Turbo:

Step 1: Gather the Necessary Parts and Tools

You will need to purchase or acquire the following items:

• 6AN fittings
• Banjo bolt with a -6AN fitting
• PTFE line
• Compression fittings that adapt -6AN to 8mm and 10mm hardlines
• Fuel filter with -6AN fittings
• Gates Barricade hose
• Other necessary adapters and fittings

Step 2: Disconnect the Fuel Lines

Start by disconnecting the fuel lines from the banjo bolt. This will involve loosening the fittings and carefully removing them from the bolt. Make sure to have a drip pan or rag handy to catch any fuel that may spill.

Step 3: Remove the Banjo Bolt

Once the fuel lines are disconnected, remove the banjo bolt from the fuel system. This may require the use of a wrench or other appropriate tool. Again, be careful not to spill any fuel.

Step 4: Install the -6AN Fitting

In place of the banjo bolt, install the -6AN fitting. Ensure that the fitting is securely tightened and sealed to prevent any fuel leaks.

Step 5: Connect the Fuel Lines

Using the appropriate adapters and fittings, connect the fuel lines to the new -6AN fitting. Make sure that all connections are secure and sealed properly.

Step 6: Test the System

Once the new fitting and fuel lines are installed, test the system for leaks. Start the vehicle and check for any signs of fuel leakage around the fitting and fuel lines. If leaks are detected, tighten the connections and retest.

Step 7: Additional Considerations

When working with fuel lines, it is important to exercise caution and ensure that all connections are secure and sealed properly. It is also recommended to replace the fuel filter and any other necessary components while accessing the fuel system.

By following these steps and paying close attention to the specific fittings and adapters required for your vehicle, you can successfully replace the banjo bolt with a -6AN fitting on a 944 Turbo. This will help ensure reliable fuel delivery and improve the overall performance of your vehicle.

Using compression fittings

When replacing the fuel lines on a 944 Turbo, you may need to replace the long lines under the car, which may now be in two sections instead of a single pipe. This may negate the need to drop the torsion bar.

One option for replacing the fuel lines is to use compression fittings. This involves cutting the old hard line and using a compression bite fitting to connect the old hard line to the new flexible line. However, it can be difficult to find a compression fitting that fits the 10mm supply line.

To install the compression fitting, cut the old hard line and use a compression bite fitting to connect it to the new flexible line. Tighten the fitting securely, using a lot of torque, to prevent leaks.

You can also use metal fittings for the metal fuel lines, which can be purchased from Lindsey Racing. For other fittings, you can order 6AN fittings from Jegs. A mm to 6AN fitting is needed for the fuel damper. You can also reuse the old fittings from the jumper line if the new fittings don't seal properly.

For the engine bay fuel lines, you can purchase a kit from lartsporscheparts on eBay. This kit includes braided lines and is relatively easy to install.

Another option is to cut the hydraulic bands off the existing fittings/lines, leaving a barbed fitting. You can then replace the lines with generic EFI-rated fuel lines and non-worm gear clamps.

When choosing fuel lines, it is important to consider the material. Braided stainless steel lines may not be the best choice for a street car, as they can hide potential damage and cracks. The braiding can also get very hot, especially if the lines are near the exhaust manifold. Instead, you can use nylon braided PTFE/Teflon hoses, which are ethanol-compatible and easier to work with.

Replacing fuel damper

The fuel pressure damper in a Porsche 944 Turbo is designed to smooth out pulses in the fuel system. It keeps the pressure constant by counteracting the negative pressure that occurs each time an injector fires.

Replacing the Fuel Damper

To replace the fuel damper, it is recommended to work on a cold engine. Work in a well-ventilated area, keep a fire extinguisher nearby, and do not smoke.

First, relieve the fuel system of any pressure. Do this by opening the fuel filler cap and/or removing the fuel pump fuse from the car's fuse panel. Then, start the car and let it idle until it runs out of fuel.

Next, locate the fuel pressure dampener. It will be on the fuel rail, usually on the front of the rail on the fuel supply line. Be careful not to confuse it with the fuel pressure regulator, which is at the rear of the fuel rail on the return line.

To decrease pressure in the fuel rail, remove the fuel pump relay and turn the engine over a few times until it runs out of fuel. The relay panel is located under the dash in earlier cars, and in the rear left side of the engine bay by the base of the windshield in later models.

Now, we will remove the fuel damper. The damper has a fuel supply line, a vacuum line, and a line out to the fuel rail. Remove the vacuum line by pulling it off—be gentle, as these lines are old and brittle.

Next, support the 24mm nut on the damper and use a 19mm wrench to loosen the fuel supply line. Fuel will escape, so be prepared to catch it and dispose of it properly.

Do not try to remove the damper from the rail line on the bottom of the damper. Instead, remove the line and damper together as one unit. Loosen the fitting where the line from the damper meets the fuel rail using a 19mm wrench. Again, fuel will escape, so be ready to catch it.

Now, support the damper and remove the 24mm nut and washer holding it to the bracket. With the line and damper removed, you can now install the new damper. Simply follow the removal steps in reverse.

Parts and Costs

The cost of replacing the fuel damper can vary. One user reported a cost of almost $700 to replace the damper, while another found a "cheap" option for $150. Used dampers can also be found for much cheaper, and some users have reported running their cars without a damper without any issues. However, this is not recommended, as it can cause the engine to run lean under acceleration.

Additional Maintenance

While replacing the fuel damper, it is recommended to also replace the fuel injectors. Additionally, the fuel lines in the Porsche 944 Turbo are known for leaking and starting fires, so it is a good idea to replace them as well.

Frequently asked questions