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85 Turbo in-tank gas return line replacement options??

arek

New member
Joined
Feb 21, 2013
Location
Louisville, KY
I could' t get the hardware to break lose under the car and got a little impatient: omg: and cut the fuel return line. See cut black plastic hose on sender. Are these available? I was thinking about just putting a coupler near the hardware that would' t budge under the car and putting in BMW high pressure fuel hose like I run in my vanagon. Thoughts?

http://s181.photobucket.com/user/microsprout/media/IMG_0443.jpg.html?sort=3&o=0

IMG_0443.jpg.html



Thanks!
 
:lol: I pulled the sender and pump from the 'top' of the car. The return line wouldn't break free from the nipple. I saw pics online of the both hoses off the later style however the Bentley said to remove the fuel return hose and plug underneath the car before the main pump which led me to think the hose doesn't come off the sender nipple. I tried to use the brake line style flare nuts to remove the hose underneath but they would not break free. I tried to post a pic with no success...the link may work.
 
'78-'85 have the hard plastic return line with the flared fitting like the the k-jet return line by the fuel filter in a k-jet car engine bay. Taking it off under the car is correct.

Find some more of that plastic stuff and warm it up and expand it a little and jam it on there? Not much fun.

Find another correct '78-'85 style sender (with a good one on it)?

???

Hiperfauto beat me to the correct way...

What condition is your current sender in? Works fine? Rusty? Rust free/works well?
 
It's an 85 K-Jet Turbo car. I guess I'll order the kit Kiperfauto posted (thanks:) but in the mean time may try to rig something up...oh and it gets better...was real careful trying to get the float ball past the opening and it popped off. I looked inside the tank and see no ball. Looks like her is a big cylinder type wall in the middle of the tank where the sender sits. I would think the ball would be floating in there...nope. Very low fuel in tank.
 
I could' t get the hardware to break lose under the car and got a little impatient: omg: and cut the fuel return line. See cut black plastic hose on sender. Are these available? I was thinking about just putting a coupler near the hardware that would' t budge under the car and putting in BMW high pressure fuel hose like I run in my vanagon. Thoughts?

The kit Ian has offered is a really good deal at that price, in my opinion.

But... You will have to install the ends on the sender nipple and the flare fitting which joins the steel return line above the axle. Doing that takes some skill with boiling water or a heat gun, and you need to be very careful not to put even the tiniest scratch in the barb connection removing the old nylon from the sender.

Then, that joint over the axle may not be in the best of shape to accept the new fitting. Unless you are in California.

The thing is, the return system is much lower pressure than is implied by the use of steel and nylon. The newer cars use ordinary fuel hose (30R7 5/16) for that entire length, under axle to sender. Granted, the newer senders have the correct nipple for 5/16 hose, but if you leave the nylon you have, intact over the barb, the 5/16 hose which I believe you will only be able to get in 30R9 now, will make a good seal with any hose clamp.

Same is true for the metal line end with its flare cut off. If you have a flaring tool, you can add a bubble to the end, but I and several others have just slid it over the Bundyweld and clamped it.

Of course the saving grace is the reduced pressure here. Your original idea has merit.

Pictures here: In the Tank
 
I ran into the same problem. I was able to use a heat gun to remove the hard plastic line. Then i trimmed the outer hose to expose more of the hard plastic. Heated the hard line and inserted a screwdriver to expand it. Heated again and slipped it over the barb. I used a small hose clamp just in case.
<a href="http://s253.photobucket.com/user/nel6211/media/Georgia%20coupe/rusty%20sender_zpsf8oa6ylr.jpg.html" target="_blank"><img src="http://i253.photobucket.com/albums/hh77/nel6211/Georgia%20coupe/rusty%20sender_zpsf8oa6ylr.jpg" border="0" alt="rusty sender photo rusty sender_zpsf8oa6ylr.jpg"/></a>
<a href="http://s253.photobucket.com/user/nel6211/media/Georgia%20coupe/tools_zpsns2peu85.jpg.html" target="_blank"><img src="http://i253.photobucket.com/albums/hh77/nel6211/Georgia%20coupe/tools_zpsns2peu85.jpg" border="0" alt="tools photo tools_zpsns2peu85.jpg"/></a>
<a href="http://s253.photobucket.com/user/nel6211/media/Georgia%20coupe/Bertone%20gas%20tank%20004_zpsh4luepwj.jpg.html" target="_blank"><img src="http://i253.photobucket.com/albums/hh77/nel6211/Georgia%20coupe/Bertone%20gas%20tank%20004_zpsh4luepwj.jpg" border="0" alt="finished with hose clamp photo Bertone gas tank 004_zpsh4luepwj.jpg"/></a>
 
I ran into the same problem. I was able to use a heat gun to remove the hard plastic line. Then i trimmed the outer hose to expose more of the hard plastic. Heated the hard line and inserted a screwdriver to expand it. Heated again and slipped it over the barb. I used a small hose clamp just in case.

Nice work and excellent photos. It is obvious to me why you dropped the tank; are you saving it or replacing it? I'm guessing saving, if you saved that sender.
 
I couldn't get under mine to do it so I cut the line and then later replaced it with fuel injection line. Seems to work fine.
 
The car I'm working on is an 81 262c that's been sitting for over 8 years. The tank was super rusty inside. I mean REALLY bad, the inside walls had started to corrode, there was no saving it. I replaced the tank with one from a running 92 245, with like new sender, pump, screen. But I needed to remove the tank in a hurry so that line with with barb got cut. All is good now, just waiting on a new fuel pump. working my way up stream. :)
<a href="http://s253.photobucket.com/user/nel6211/media/Georgia%20coupe/old%20and%20new_zpsnvqulpze.jpg.html" target="_blank"><img src="http://i253.photobucket.com/albums/hh77/nel6211/Georgia%20coupe/old%20and%20new_zpsnvqulpze.jpg" border="0" alt=""new" and old photo old and new_zpsnvqulpze.jpg"/></a>
 
Also a side note, if you need the hard plastic line. The over flow gas drain is made of the same hard plastic and I think it is right diameter.
 
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