Custom fuel pipe for Bosch K-Jetronic
Discussion
Hello folks,
The connection between the rigid petrol feed pipe to the fuel filter on the XR4i was originally by a semi rigid plastic pipe. At one end was a quickly detachable push on connector to fit over the 8mm steel fuel pipe, at the other end was a banjo to connect to the fuel filter. The plastic pipe itself appears to have been some kind of heat shrinking plastic, i.e. it was shrunk onto the fittings and is far too rigid to push fittings in or pull them out, yet is still a bit flexible. At the banjo end there is a piece of flexible rubber pipe on top of the plastic pipe, with two metal crimp rings to clamp over the banjo barb, at the QD fitting end there is nothing. There is a 90 degree bend in the middle. Pressure is about 75psi off the top of my head.
Unfortunately the original QD fitting had to be broken off to be removed a couple of years ago. On the advice of a Ford dealer and a specialist breaker I used normal flexi injection hose with fuel pipe clips but unfortunately in about 2k miles it has removed itself completely once, leaked very heavily another time and weeped a few times which I am not happy about. Noone wants to sell me an original in case it fails. Therefore I would like to get a replacement made to the same spec as the original. Can anyone recommend a company that can make such a thing, preferably in East Anglia though if necessary I could cope even with abroad?
The connection between the rigid petrol feed pipe to the fuel filter on the XR4i was originally by a semi rigid plastic pipe. At one end was a quickly detachable push on connector to fit over the 8mm steel fuel pipe, at the other end was a banjo to connect to the fuel filter. The plastic pipe itself appears to have been some kind of heat shrinking plastic, i.e. it was shrunk onto the fittings and is far too rigid to push fittings in or pull them out, yet is still a bit flexible. At the banjo end there is a piece of flexible rubber pipe on top of the plastic pipe, with two metal crimp rings to clamp over the banjo barb, at the QD fitting end there is nothing. There is a 90 degree bend in the middle. Pressure is about 75psi off the top of my head.
Unfortunately the original QD fitting had to be broken off to be removed a couple of years ago. On the advice of a Ford dealer and a specialist breaker I used normal flexi injection hose with fuel pipe clips but unfortunately in about 2k miles it has removed itself completely once, leaked very heavily another time and weeped a few times which I am not happy about. Noone wants to sell me an original in case it fails. Therefore I would like to get a replacement made to the same spec as the original. Can anyone recommend a company that can make such a thing, preferably in East Anglia though if necessary I could cope even with abroad?
So exactly which bits are you trying to join ?
2 pieces of nylon tubing the same size ? Nylon to steel ? Rubber ?
Whilst it wouldnt be my first choice on fuel lines, I have seen the pneumatic push fit stuff used successfully. And they are very cheap and easy to use.
This type of thing.
Many water/methanol injection systems use them. Anywhere that sells air tools etc will stock them, maybe £1 or 2 each
http://uk.rs-online.com/web/p/fittings-push-in/210...
And it isnt heat shrink. They just manage to force it on somehow so it s a tight fit over the barb.
2 pieces of nylon tubing the same size ? Nylon to steel ? Rubber ?
Whilst it wouldnt be my first choice on fuel lines, I have seen the pneumatic push fit stuff used successfully. And they are very cheap and easy to use.
This type of thing.
Many water/methanol injection systems use them. Anywhere that sells air tools etc will stock them, maybe £1 or 2 each
http://uk.rs-online.com/web/p/fittings-push-in/210...
And it isnt heat shrink. They just manage to force it on somehow so it s a tight fit over the barb.
At one end of the plastic pipe is a fitting pushing onto the outside of the rigid fuel feed pipe which is 8mm diameter (food grade stainless steel in this instance!) and inside the semi flexible plastic pipe, the other end carries a banjo to connect to the fuel filter.
The pneumatic push fit stuff looks interesting, I hadn't thought of trying that.
The pneumatic push fit stuff looks interesting, I hadn't thought of trying that.
Still not sure which bit you need repaired. Usually the banjo fitting is the same affair. Where the nylon is pushed over a small barb on the banjo fitting.
Here is the car I seen using the fittings a good few years ago. They can certainly handle the pressure no problem. Whether petrol would degrade the o-rings over time...who knows. In theory they shouldnt. And if they did...they are so cheap they could be replaced on a 6 month or yearly basis if need be, and only take a few seconds to change
Here is the car I seen using the fittings a good few years ago. They can certainly handle the pressure no problem. Whether petrol would degrade the o-rings over time...who knows. In theory they shouldnt. And if they did...they are so cheap they could be replaced on a 6 month or yearly basis if need be, and only take a few seconds to change
The fuel pipe in question is the one connecting to the fuel filter in the photo below (this is in the left hand side of the engine bay, mounted on the inner wing):
The replacement injection hose is the problem (and is fitted as advised by a Ford dealer and a specialist scrappy), I want to make or have made something similar to the original. The banjo on the original is as below:
And the quickly detachable coupling is as below (the one in the photo was cut out from a differently configured pipe on a different model):
The replacement injection hose is the problem (and is fitted as advised by a Ford dealer and a specialist scrappy), I want to make or have made something similar to the original. The banjo on the original is as below:
And the quickly detachable coupling is as below (the one in the photo was cut out from a differently configured pipe on a different model):
Matthew-TMM said:
The fuel pipe in question is the one connecting to the fuel filter in the photo below (this is in the left hand side of the engine bay, mounted on the inner wing):
The replacement injection hose is the problem (and is fitted as advised by a Ford dealer and a specialist scrappy), I want to make or have made something similar to the original. The banjo on the original is as below:
And the quickly detachable coupling is as below (the one in the photo was cut out from a differently configured pipe on a different model):
Pirtek or similar can make these EFI OE pipes for you they warm then freeze that hard plastic pipe onto those Banjo barbed fittings The replacement injection hose is the problem (and is fitted as advised by a Ford dealer and a specialist scrappy), I want to make or have made something similar to the original. The banjo on the original is as below:
And the quickly detachable coupling is as below (the one in the photo was cut out from a differently configured pipe on a different model):
I must say I don't like your temporary repair 
the Bosch K Jetronic system primary pressure is around 75psi if I remember correctly and that hose & screw clips on your repair picture just wont do IMO 
Edited by Sardonicus on Thursday 2nd May 14:18
kevwalker245 said:
I know its been a while, but can you tell me how you removed the quick release coupling from the steel fuel pipe, as mine wont move.
best regards
If you look at the end of the coupling on the steel pipe end you should see a couple of holes next to the pipe. Bend a bit of stiff wire so that you can push into both holes at the same time, it should come off quite easliy. I wish someone had told me before I broke the first one!best regards
Sardonicus said:
Pirtek or similar can make these EFI OE pipes for you they warm then freeze that hard plastic pipe onto those Banjo barbed fittings I must say I don't like your temporary repair the Bosch K Jetronic system primary pressure is around 75psi if I remember correctly and that hose & screw clips on your repair picture just wont do IMO
I didn't like the repair either, even before I did it. I was advised to do it that way by a Ford main dealer and a specialist XR4i and XR4x4 breaker, and as no solution was forthcoming and time was of the essence (impending house move) I went ahead with it. It came off twice, prompting me to start this thread, though at least the fuel pump relay cut out when it happened. I must say I don't like your temporary repair the Bosch K Jetronic system primary pressure is around 75psi if I remember correctly and that hose & screw clips on your repair picture just wont do IMO I ended up making my own pipe up using the coupling in the photo; I cut the remains of the old nylon pipe from it using a stanley knife (carefully as I didn't want to damage the fitting) and used new nylon fuel pipe I bought from a diesel injection factor. The nylon pipe has to be pretty hot, boiling water won't cut the mustard, I had to very carefully heat it under the grill (get it too hot and it blisters). Final result is as per original using the proper fittings and has been fine since.
Matthew-TMM said:
I didn't like the repair either, even before I did it. I was advised to do it that way by a Ford main dealer and a specialist XR4i and XR4x4 breaker, and as no solution was forthcoming and time was of the essence (impending house move) I went ahead with it. It came off twice, prompting me to start this thread, though at least the fuel pump relay cut out when it happened.
I ended up making my own pipe up using the coupling in the photo; I cut the remains of the old nylon pipe from it using a stanley knife (carefully as I didn't want to damage the fitting) and used new nylon fuel pipe I bought from a diesel injection factor. The nylon pipe has to be pretty hot, boiling water won't cut the mustard, I had to very carefully heat it under the grill (get it too hot and it blisters). Final result is as per original using the proper fittings and has been fine since.
Nice one I ended up making my own pipe up using the coupling in the photo; I cut the remains of the old nylon pipe from it using a stanley knife (carefully as I didn't want to damage the fitting) and used new nylon fuel pipe I bought from a diesel injection factor. The nylon pipe has to be pretty hot, boiling water won't cut the mustard, I had to very carefully heat it under the grill (get it too hot and it blisters). Final result is as per original using the proper fittings and has been fine since.
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