The vehicle for humanity approaches road test, maybe...

'90 244 DL

In attempting to prepare for one of the last steps before inspection (hopefully, please, oh please!) I am trying to find the dimensions to replace both the supply and return fuel lines which have pinhole leaks. I'd like to take all the parts with me when it goes to the shop, and maybe help the mechanic out a bit.

As I learned when I replaced the pumps/filter on Paul, I'm not doing a patch job, nor am I starting him and pumping debris into the fuel pressure regulator and clogging the line. With the amount of work/parts I have into it, I really don't want an astronomical shop bill on top of everything else.

I know the fittings at the filter are banjo, hose clamps at the tank end, and I believe I've read that the return line is 5/16" diameter. I don't know what the fittings at the fpr are, the overall length of either long line, nor the diameter of the supply line. Or anything else I might be missing.

Also, I've heard rumors about using a plastic line for the return line as an upgrade, and wondering what the advantages are, other than corrosion resistance. I live in salty, occasionally very cold western NY, and am concerned about the possibility of cold-brittle, as well as the corrosion.

I'd do this job myself in the summer, but cold floors, no vehicle lift and limited room to maneuver make me unwilling to reattempt this in the winter. Any recommendations or other answers would be most intensely appreciated! Thank you!

I think I can, I think I can, I think I can get Junior on the road!
ezsha
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'84 244, Peter, never drove. Robbed to fix Paul, '86 244 - drove for 2 years; holey saint now, passing parts to Paul Jr, '90 244, yet to drive. Friends w/ '90 245, jokingly aka Mary, (pregnant sedan & completes PPM trilogy). Daughter to unnamed '90 745.