3.4 Project Begins!!!! - 986 Forum - The Community for Porsche Boxster & Cayman Owners

JAAY · 03-11-2009, 02:53 PM

The little black fitting in the lower right corner of the photos is our stock fuel return connection. I was going to use this but then looking further into how I am going to make these connections I don't think that is a good choice. I stripped back the factory lines off the rails. There are barb fittings on them. I am going to run a new fuel line off the return barb straight to the factory fitting that is metal. It is a nice tight fit as it is but I am going to put a hose clamp on it. For the fuel feed you can see the photo of the fitting that I put together to run from the 996 rail over the motor to the factory fuel line. The factory fuel feed line I also took off the factory line and stripped it back to just the metal line. I am going to just run new fuel hose over to that metal line and clamp that also. Sorry for my terrible sentence structure.

The photo below if you look on the outer left side of the rail, by the way this is now the drivers side of the motor this will be on, on the outer side you will see the old welded on return rail. I am bypassing this just to save on connections. I figure the fewer the better. So now the return line is coming directly from the fuel pressure regulator side.

tholyoak · 03-11-2009, 03:01 PM

I would reconsider ditching the factory fitting for the return line on the chassis. It works just fine with aeroquip -4 socketless hose and putting a hose directly on the metal line under the car is not a good idea IMHO. It is a smooth pipe with no raised surface or barbing for the hose clamp to. Smooth hose on smooth pipe clamp or not does not make for a good solution, especially when fuel is involved. Especially when it points right at the exhaust headers.

-Todd

JAAY · 03-11-2009, 05:48 PM

I understand your concern about the return. I haven't got to deep into the return line. Is there a spot where the return line will unscrew and I can get a aeroquip fitting on it? I think that the fuel supply will be fine with a hose clamp being that there is a flare in the line.

Thanks again

JAAY · 03-11-2009, 06:20 PM

I read your post wrong. I was going to reuse the factory fitting and was toying with the idea of putting the line directly on the old metal line. But you brought up a good point with the non barb or flare on the factory return line. So putting the fuel line onto the factory fitting with aeroquip socketless line, I would think that you would have to put a small clamp on that also.....??? Let me know if I am heading in the right direction now.

JAAY · 03-11-2009, 06:39 PM

I ran out to the garage and just fitted the fitting on the line quick. It is not cut to length, I will do that once the motor is in. I threw a clamp on it and just wanted to know if this is what you would think is better.

This is a picture of the metal line that we are talking about. This is located right behind the drivers seat kind of underneath the car.

tholyoak · 03-13-2009, 10:13 AM

Yes, the return line looks fine. You don't need to cut the supply line. You can get an adapter fitting to fit the metric threads on the current supply line fitting and use AN hose and a metric fitting to extend to the 996 fuel rail. That way everything is completely reversible.

-Todd

JAAY · 03-13-2009, 11:36 AM

OK.. I didn't trace the fuel feed back that far. Where does it unscrew. You are talking about the feed line not on the rail right?