SS Fuel Line Installation, with pictures Options

[billd]

I started out to restore my 73 2.0L to its original D-Jetronic fuel injection. At some point I decided that I while I was working on the fuel system I might as well replace the plastic lines with stainless steel and relocate the pump. Here are some pictures with commentary of the fuel line upgrade.

Overall the fuel line install was fairly easy. It would have been much easier if I hadn't decided to run one solid line from the tank all the way to by the MPS sensor. If I did this over again I would do everything the same except that the solid lines would stop at the right side of the firewall and I'd run hose from there.

First, I removed the interior and pulled the fuel tank. Here is a photo of the tank halfway out. The hoses on the tank were long enough that I didn't need to disconnect them through the service hole below the tank. I was able to lift the tank to this position and then disconnect the hoses from above. The new hoses I installed are also long enough to permit access from above.

[billd]

QUOTE (smooth_eddy @ Sep 16 2005, 02:57 PM)

From your last picture it looks like you used 2 different types of hose under the gas tank.  What was the reason?  Also, from an old post the ends of the metal fuel line was threaded so the hose gets a good bite.  Do you think there is any chance of your connections coming apart?   This is my next project.  I am glad it can be done with the engine in place.  How long did it take including removing and replacing the interior?  Thanks,  Eddy

The lines out of the fuel tank are two very different sizes, so I used different size hose. I used 9mm hose on the line from the tank to the fuel filter, 7mm hose from the return line to the tank. I chose to use 5/16 hose on the line from the pump to the tank. 9mm would have worked as well, but 5/16 was a more snug fit on the 5/16 OD SS line.

To get the hoses to grip on the SS line I notched the SS line with a file and die grinder. About four notches, one every 1/4 inch at about four places around the circumference of the tube. I also degreased the lines with solvent to get them real clean before I slipped the hoses on. I'll keep an eye on them, but I don't think the hoses will come off.

I did this project over a period of several weeks, grabbing an hour here or there as time allowed. A rough guess on time is:
Remove fuel tank, interior, and old lines - 1 hour.
Fit new lines in place - this took me about 3 hours, but if you ended the lines at the right side of the firewall I think you could do it in 1 to 1.5 hours.
Clamp new lines to firewall - 0.5 hour.
Fabricate clamp and clamp lines under tank - this took me about 1 hour, but you could omit this step.
Reinstall fuel tank - 0.5 hours.
Reinstall interior - I haven't done this yet. I'll guess 1.5 hours.