Check Those FI Hoses!

Check Those FI Hoses!

Joined: June 6th, 2008, 12:05 am

October 11th, 2008, 3:08 am #1

After staggering out of my dentist's office this morning, my trusty '86 eXxie (135 k miles) didn't start on the first crank rev. Hrmmph. After some grinding it kicked in, but was kinda' rough. "Aw, I'll check it when I get home and recover some feeling in my face." As I began backing out of the parking spot it began losing RPM. Pressing / feathering the pedal didn't help as it stalled out. I tried cranking again when I noticed out the window a river of "fluid" headed toward the gutter. "WTF?!"

As soon as I opened the door I smelled the gasoline and a cold shiver went through the parts of my body that weren't numb already. Opening the engine deck revealed a thoroughly gasoline soaked engine and engine compartment. The original cotton braid/rubber HP fuel line from the top/output of the fuel filter to the metal line had split! And the split was pointed horizontally toward the engine. (of course)

To get to the hose clamp on the filter end of the hose I had to remove the air filter can lid and hose. This revealed the bottom of the filter can was filled with ingested fuel.

So, the Great Bertone Muse spared my eXxie -- and me! -- to remind you all to check those hoses!

And if your fuel pump runs when the engine is not turning (the condition mine was in when I first got it) pry the lid off the air flow sensor and bend that vane! I'm glad I did. Really glad.

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Joined: December 21st, 2004, 3:04 am

October 11th, 2008, 6:41 am #2



My best,



Tony
Black Tooth and me... since 1983!
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Duane K Estill (Corinth, Mississippi)
Duane K Estill (Corinth, Mississippi)

October 11th, 2008, 2:42 pm #3

After staggering out of my dentist's office this morning, my trusty '86 eXxie (135 k miles) didn't start on the first crank rev. Hrmmph. After some grinding it kicked in, but was kinda' rough. "Aw, I'll check it when I get home and recover some feeling in my face." As I began backing out of the parking spot it began losing RPM. Pressing / feathering the pedal didn't help as it stalled out. I tried cranking again when I noticed out the window a river of "fluid" headed toward the gutter. "WTF?!"

As soon as I opened the door I smelled the gasoline and a cold shiver went through the parts of my body that weren't numb already. Opening the engine deck revealed a thoroughly gasoline soaked engine and engine compartment. The original cotton braid/rubber HP fuel line from the top/output of the fuel filter to the metal line had split! And the split was pointed horizontally toward the engine. (of course)

To get to the hose clamp on the filter end of the hose I had to remove the air filter can lid and hose. This revealed the bottom of the filter can was filled with ingested fuel.

So, the Great Bertone Muse spared my eXxie -- and me! -- to remind you all to check those hoses!

And if your fuel pump runs when the engine is not turning (the condition mine was in when I first got it) pry the lid off the air flow sensor and bend that vane! I'm glad I did. Really glad.
I think it's called "observation and appropriate action," I had a ball joint go out on the Spider a few months ago, at low speed, kerPLLUNK right there pulling onto a four lane. There is a moment in there where it seems chaotic. It requires observation and appropriate action to simply do what needs to be done to get things livable in the (very) short term.

By the way...the "staggering out of the dentist" office and numbness remarks were hilarious.
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Joined: June 6th, 2008, 12:05 am

October 11th, 2008, 5:22 pm #4

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Last edited by OldZeb on October 11th, 2008, 5:23 pm, edited 1 time in total.
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Chuck34
Chuck34

October 11th, 2008, 11:45 pm #5

After staggering out of my dentist's office this morning, my trusty '86 eXxie (135 k miles) didn't start on the first crank rev. Hrmmph. After some grinding it kicked in, but was kinda' rough. "Aw, I'll check it when I get home and recover some feeling in my face." As I began backing out of the parking spot it began losing RPM. Pressing / feathering the pedal didn't help as it stalled out. I tried cranking again when I noticed out the window a river of "fluid" headed toward the gutter. "WTF?!"

As soon as I opened the door I smelled the gasoline and a cold shiver went through the parts of my body that weren't numb already. Opening the engine deck revealed a thoroughly gasoline soaked engine and engine compartment. The original cotton braid/rubber HP fuel line from the top/output of the fuel filter to the metal line had split! And the split was pointed horizontally toward the engine. (of course)

To get to the hose clamp on the filter end of the hose I had to remove the air filter can lid and hose. This revealed the bottom of the filter can was filled with ingested fuel.

So, the Great Bertone Muse spared my eXxie -- and me! -- to remind you all to check those hoses!

And if your fuel pump runs when the engine is not turning (the condition mine was in when I first got it) pry the lid off the air flow sensor and bend that vane! I'm glad I did. Really glad.
The cotton covered lines are no good. Replace them all with FI rated rubber hose. There's probably a recall on those anyways. And make sure you use real FI clamps.
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Duane K Estill (Corinth, Mississippi)
Duane K Estill (Corinth, Mississippi)

October 12th, 2008, 2:05 am #6

What's a good source for that braided high pressure hose to replace the cotton coated stuff? My mechanic used to get it from BMW dealers but either it got too pricey or something. I would like to know of a source for that.
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Joined: August 29th, 2005, 4:22 am

October 12th, 2008, 3:34 pm #8

The cotton covered lines are no good. Replace them all with FI rated rubber hose. There's probably a recall on those anyways. And make sure you use real FI clamps.
And stock on many VW, BMW and yes Fiat cars using L-Jet. There are some braided hose that is not rated for F.I. pressures, usually in smaller diameters for vacuum lines, but if you buy it from a reputable source it should be correct and clearly labeled.

Also available as naked rubber hose, for instance I have some purchased locally. The difficulty comes in getting the correct I.D. Our cars and others using Bosch F.I. need 7.5mm I.D., but I have used 5/16" I.D. (7.9mm) successfully with the stock barb/collar setup. If you use claps, be sure to use F.I. clamps with smooth straps and rolled edges.

Replacing fuel lines is very important. If your lines appear cracked on the outside, the inside will be completely cracked. If you smell any fuel on the outside it is only a matter of time before the line splits.

Gregory Smith

'87 Bertone X1/9 Corsa
'88 VW Vanagon
Olympia, Washington, USA
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Joined: October 15th, 2007, 3:50 am

October 13th, 2008, 3:52 pm #9

What's a good source for that braided high pressure hose to replace the cotton coated stuff? My mechanic used to get it from BMW dealers but either it got too pricey or something. I would like to know of a source for that.
From Aircraft Spruce.

http://www.aircraftspruce.com/catalog/a ... ato156.php

With clamps:

Mc Master Carr# 53175K27 or K28

$12.80 per foot, difficult to work with, but is sure holds up well. This is used in all of the EFI hoses on my X. It's been totally problem free and should last for a while.
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Joined: August 29th, 2005, 4:22 am

October 15th, 2008, 6:45 pm #10

And stock on many VW, BMW and yes Fiat cars using L-Jet. There are some braided hose that is not rated for F.I. pressures, usually in smaller diameters for vacuum lines, but if you buy it from a reputable source it should be correct and clearly labeled.

Also available as naked rubber hose, for instance I have some purchased locally. The difficulty comes in getting the correct I.D. Our cars and others using Bosch F.I. need 7.5mm I.D., but I have used 5/16" I.D. (7.9mm) successfully with the stock barb/collar setup. If you use claps, be sure to use F.I. clamps with smooth straps and rolled edges.

Replacing fuel lines is very important. If your lines appear cracked on the outside, the inside will be completely cracked. If you smell any fuel on the outside it is only a matter of time before the line splits.

Gregory Smith

'87 Bertone X1/9 Corsa
'88 VW Vanagon
Olympia, Washington, USA
After 20 years, they look like this inside:


A little scary!

Gregory Smith

'87 Bertone X1/9 Corsa
'88 VW Vanagon
Olympia, Washington, USA
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