• Eric
  • Member
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  • Registered: 2010-07-11
  • Posts: 43

Topic: Replace Fuel Line

Hi... I just bought a 1968 Karmann Ghia...  (basically same chassis as beetle)

I'm working on the teardown and I want to get the engine running first... the fuel line appears to have broken right where it exits the back part of the main tunnel...   What do I do???

Do I replace the entire fuel line?... if so... How?

all my searches come up with some article from a 2004 magazine... but I don't know where to find this magazine... soooo if your suggestion is to read the magazine, please tell me where to find it  smile

I was thinking of running a steel conduit around the small channel between the rocker pannel and the side of teh floor pan and running the fuel line through that conduit...  any suggestions???

thanks!

1968 VW  Karmann Ghia Convertible
  • From: B.C.Canada
  • Registered: 2005-01-26
  • Posts: 2,586

Re: Replace Fuel Line

Bruce said " Easy. With the front cover plates off, the shifter out, the inspection cover off, and the left rear wheel off, it takes 10min with a helper.

Place a light bulb in the tunnel at the rear inspection hole (shift rod coupler disconnected from trans and pushed aside).
Then feed the new line through the front hole, watching down the tunnel as you go. Feed it under the cross brace for the front of the clutch tube. When it gets to the inspection hole at the rear, stop. Insert a welding rod into the left frame horn hole until it comes into the inspection hole. put the welding rod inside the new fuel line to act as a guide as you continue to feed the fuel line out the hole in the fork. Bend a slight S shape to the line so the grommet fits well."

jim

'71 SB(DD only 79K(now 84K miles) & '78 FI Westy (project)
PO of '65 Beetle in '69, '70 Crewcab & '70 Ghia in '77
'71 Super inside rear vents now available
http://www.openroad.ca/volkswebbin/view … p?id=85915
  • From: B.C.Canada
  • Registered: 2005-01-26
  • Posts: 2,586

Re: Replace Fuel Line

Bill May said" you do not have to cut holes in frame to feed new line inside the tunnel. alan willis  did this on dave markel's 57 ragtop in less than 5 minutes. it takes me 15 minutes. jack up beetle rear and place on jack stands. remove left rear wheel. grab old fuel line with vice grips and pull it out-you only have to get enough of it out so new 1/4" hydraulic or brake line tubing can be inserted into original hole coming out of frame. remove rear coupler cover plate. have helper feed new line thru access hole so it keeps moving forward. remove shifter. use shifter hole to readjust line movement forward. jack up front after replacing rear tire. remove gas tank. grab old line under tank with vice grips and pull it out. reach thru front access cover to guide tube outwards so it can be bent upwards and by pulling line  backwards to line up bend to come out tube opening under gas tank. cut off excess tubing to length. install new hose at both ends. by having one guy feeding and one guy moving tube inside tunnel around obstacles"

jim

'71 SB(DD only 79K(now 84K miles) & '78 FI Westy (project)
PO of '65 Beetle in '69, '70 Crewcab & '70 Ghia in '77
'71 Super inside rear vents now available
http://www.openroad.ca/volkswebbin/view … p?id=85915
  • Eric
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  • Registered: 2010-07-11
  • Posts: 43

Re: Replace Fuel Line

Awesome!  Thanks everyone for the replies!  I'm going to try it out this week and let you know how it goes...   Thanks!

1968 VW  Karmann Ghia Convertible
  • From: somewhere over the rainbow USA
  • Registered: 2006-07-26
  • Posts: 1,882

Re: Replace Fuel Line

I would like to see someone do this in 15 minutes. I know what is written up about it on the sites.
Not saying it can't be done but good luck. Just don't expect a 15 minute job.

burrhead

A wise man makes his own decisions, an ignorant man follows public opinion.
  • Registered: 2009-06-25
  • Posts: 554

Re: Replace Fuel Line

burrhead wrote:

I would like to see someone do this in 15 minutes. I know what is written up about it on the sites.
Not saying it can't be done but good luck. Just don't expect a 15 minute job.

Certainly not the first time, and probably not the second time  wink

Paul

  • From: Washington, Indiana
  • Registered: 2004-03-27
  • Posts: 1,423

Re: Replace Fuel Line

15 minutes....HAHAHAHAHHA

                                                                           Yancey

Yancey's Website

  • From: Cincinnati, Ohio
  • Registered: 2005-09-10
  • Posts: 2,318

Re: Replace Fuel Line

Yancey wrote:

15 minutes....HAHAHAHAHHA

                                                                           Yancey

Yeah...15 minutes...no way!  It would take me 15 minutes just to remove all the crap I have piled on top of the floor jack & jacks stands. wink

- Nick

1979 Super Beetle Convertible
  • From: B.C.Canada
  • Registered: 2005-01-26
  • Posts: 2,586

Re: Replace Fuel Line

I have never done this, I'm just passing on info. The time they claim is not as important as you guys who've done this verifying that the steps are correct and complete. That's why I didn't just post a link to it.

I've had many jobs take a lot of time due to one stuck nut. (go for it Burr)

I wonder what it's like to work on a new car with nice new shiny nuts and bolts?

jim

'71 SB(DD only 79K(now 84K miles) & '78 FI Westy (project)
PO of '65 Beetle in '69, '70 Crewcab & '70 Ghia in '77
'71 Super inside rear vents now available
http://www.openroad.ca/volkswebbin/view … p?id=85915
  • From: Cincinnati, Ohio
  • Registered: 2005-09-10
  • Posts: 2,318

Re: Replace Fuel Line

I'm with ya Jim.  The actual time it takes to do the job isn't so important (whether it's 15min, 20, 60, or 2 hours.  Knowing that the fuel line that runs thru the tunnel can be replaced, knowing the steps to do it, and that it's not a major major project are what's most important. IMHO smile

- Nick

1979 Super Beetle Convertible
  • Registered: 2009-06-25
  • Posts: 554

Re: Replace Fuel Line

jamesdagg wrote:

I wonder what it's like to work on a new car with nice new shiny nuts and bolts?

If it's got nice new shiny nuts and bolts, it shouldn't NEED any work, lol.
I did replace the inner tie rods on both my car and the wife's van. One tug with a breaker bar and I unscrewed them the rest of the way by hand. They were clean and shiny on the part covered by the boot, but even the unprotected lock nut came off easily. Having the tool made for the job helps, even if it did cost $47.95! Can't complain about having to do the job despite not being rusted yet; the car has 160,000 miles, the van 168,000.

The Ghia, on the other hand, did not give me any real problems either when I replaced the tie rods AND the steering box... despite being 40 years old  smile

Paul

  • Registered: 2009-06-25
  • Posts: 554

Re: Replace Fuel Line

Bug In My Nose wrote:

Knowing that the fuel line that runs thru the tunnel can be replaced, knowing the steps to do it, and that it's not a major major project are what's most important. IMHO smile

Definetly the most important point. Anyone seen some someone run a new fuel line all the way under the car, or through the passenger compartment because they thought the tunnel job was near impossible?

I thought the shifter bushing was going to be a hard job, until I did it. Now I wouldn't mind doing it again for fun! Well ok, maybe not for fun... but I'd wouldn't mind giving someone else a hand with it.

Paul

Last edited by Altema (2010-07-18 06:52:15)

  • From: Cincinnati, Ohio
  • Registered: 2005-09-10
  • Posts: 2,318

Re: Replace Fuel Line

Altema wrote:
Bug In My Nose wrote:

Knowing that the fuel line that runs thru the tunnel can be replaced, knowing the steps to do it, and that it's not a major major project are what's most important. IMHO smile

Definetly the most important point. Anyone seen some someone run a new fuel line all the way under the car, or through the passenger compartment because they though the tunnel job was near impossible?

EXACTLY what I was thinking!  On the surface you would think that replacing that metal fuel line (in the tunnel) would be next to impossible.  Especially if someone thought the original engineers didn't design it to be replaced.  But knowing it can be replaced...and not too big of a job...keeps folks from doing what you mentioned (running a fuel line underneath the car). sad

- Nick

1979 Super Beetle Convertible
  • From: somewhere over the rainbow USA
  • Registered: 2006-07-26
  • Posts: 1,882

Re: Replace Fuel Line

All I am saying is that let's be realistic on the time of replacing stuff on these old cars. Sure SOME can do it in that time but probably not on the first or second try.
I can replace all 4 ball joints on the car in under 1 hour, starting with the car on the ground and ending up with the car on the ground. Or replacing a generator in under 1/2 hour with all 4 backing bolts in place with the engine in the car. But it took me many years to  be able to do this. And most the time you have some obstacle  or Murphey in the way to screw things up.
Stuck nut jim? HHHMMM

burrhead

A wise man makes his own decisions, an ignorant man follows public opinion.
  • Registered: 2009-06-25
  • Posts: 554

Re: Replace Fuel Line

burrhead wrote:

Stuck nut jim? HHHMMM

I think there's a medical term for that...

lol