Close call with the S6 tonight

[SteelyS6]

Had a brutal day at work, frozen brakes, frozen valves, etc was just dying to get away from work. Started the car and was talking to one of my mechanics and thought I smelled fuel. Car was very cold and I just thought it was running rich. Got in after letting it warm up and wow the smell of gas was strong. Opened the hood and has was just spewing out of fuel line going to fuel rail, was already starting to burn and smoke on the exhaust manifold! Guess I will be ordering the fuel line tomorrow or having one made up. Glad it didn't escalate.

[bpark1210]

Wow glad to hear it didn't ignite into a fire. Good luck and let us know if you need anything.

[PaperToast]

good catch, didnt need to see a thread about a bbq'd s6

[4rings2turbos]

Oh man! That's crazy! I've had the smell before and replaced the line a couple times but that's crazy it was spewing! Glad you caught it right away.

[SteelyS6]

Yup heard of them weeping in the cold but this was bad. Todays weather was working all sorts of miracles on man and machinery, -28 degrees celsius without windchill. I am so done with winter at this point. I just want the weather to start warming up so I can really focus on my Audi projects for the year. Starting the partout of my 02 Highland Green 6 spd this weekend, everything will be available so if you know anyone interested they can contact me here. Will post a proper add once the major parts are pulled.

[mr_dave]

Any pictures of exactly what failed? Sounds like some preventative maintenance I'd want to do since my wife drives our kids around in the S6.

[Chris_s1]

Be safe man, especially those of you out in the cold!! In Miami we don't deal with that, but it sure get's rainy! Glad you caught it before it got worse.

[SteelyS6]

Any pictures of exactly what failed? Sounds like some preventative maintenance I'd want to do since my wife drives our kids around in the S6.

I will take some pictures tomorrow after work when I change the hose. They are known to leak on older C5's, allroads have been known to develop leaky injectors in the cold. Told my wife today when I got home if she ever smells gas, pull off the road and shut the car off.

[carmudgeon]

I'm assuming it was the pressure side flexible line that connects the hard line to the fuel rail. If so it's a discontinued part on the 4.2. The good news is it's easy to fabricate a replacement out of 5/16" rubber fuel line and a couple of clamps. If you carefully cut away the crimped end you'll end up with a metal hose barb that you can thread onto the fuel rail and connect a new line to.

[SteelyS6]

That's the line, that's not what I wanted to hear though "discontinued ". Guess we will be getting some fuel hose and some good quality gear clamps.

[SteelyS6]

Confirmed that Audi does not have this line, and that the people working their parts counter are morons. I hate dealerships.

[4rings2turbos]

Is it longer than the 2.7T line? I imagine that would fit on both ends if it's long enough. Gonna go in the garage and look at the two S6s and see what it looks like.

[carmudgeon]

The OE is a molded hose, you can also buy the straight hose (I think for a B6?, double check the part number, 4B0201541C) and trim it to length.

[carmudgeon]

It baffles me that Audi doesn't stock that hose. I can buy virtually any other rubber hose under the hood no matter how insignificant. But the main feed line that poses a major fire hazard if it bursts? Nope.

[SteelyS6]

Baffling for sure, if I didn't have to run my partout allroad I thought about taking that one.

[carmudgeon]

Interesting, its discontinued for the 4.2 in the 2002 A6/S6, but a 2003 Allroad with a 4.2 lists the supply and return as available, 4Z7201214A for the pair.

[NuGGet_PuFFer]

What is the big deal with getting some fuel line and clamps? I'd do that before over-paying for a rubber hose from the stealership anyways.

[carmudgeon]

I included the part numbers in case someone comes across this thread in the future, some people like to keep their cars original.

I went the cheap route, all it cost was $10 for parts and 10 minutes arguing with the kid behind the counter that fuel hose and fuel line are not the same thing.

[SteelyS6]

Will be repairing with fuel line and clamps i just picked up, total cost $15 Canadian so like $5 US ;)

[02 A6 2.7T]

Will be repairing with fuel line and clamps i just picked up, total cost $15 Canadian so like $5 US ;)

Hopefully that $15 included GST and PST

[julex]

as said above, trim the metal sleeve off and you will be left with normal barb and fuel line. Buy oetiker clamps and it will last forever (don't use gear/worm clamp unless you want to really have a fire in there).

[NuGGet_PuFFer]

as said above, trim the metal sleeve off and you will be left with normal barb and fuel line. Buy oetiker clamps and it will last forever (don't use gear/worm clamp unless you want to really have a fire in there).

Oetiker clamps with the proper pliers are fucking amazeballz, that is all.

[SteelyS6]

I have some Oetiker clamps but don't have the pliers and the size I do have is a little big. think I bought them for a P/S cooler line fix. Probably going to use proper fuel line clamps, not a regular gear clamp. What pressure does this line see anyways?

[NuGGet_PuFFer]

I have some Oetiker clamps but don't have the pliers and the size I do have is a little big. think I bought them for a P/S cooler line fix. Probably going to use proper fuel line clamps, not a regular gear clamp. What pressure does this line see anyways?

McMaster-Carr.com has all sizes and the regular and also right angle pliers for cheap. U can also get the stuff u need to build your own boost pressure tester, I think either the APR or AWE site has the link/list of parts needed.

[bpark1210]

This reminds me I should probably replace my fuel line soon. It was disentegrated to bare metal and prevented me from finishing my VCG's on the passenger bank.



Would there be any harm in reusing the OE hose clamp or am I better off w/ an Oetiker style clamp? I have both available and will prob just source a standard fuel line like carmudgeon already noted.

[PaperToast]

Confirmed that Audi does not have this line, and that the people working their parts counter are morons. I hate dealerships.

lol; its too bad your not a lot closer to me, i have a parts guy at a vw dealer in denver that can get me just about anything, nothing yet that has stumped him

[SteelyS6]

All fixed up. Couple of pics of the culprit.
[IMG][/IMG]
^The fuel line in the middle that has the metal crimp was leaking around the crimp, another shot of the line going to the hardliners behind airbox
[IMG][/IMG]

And a shot of the salvaged fitting with new fuel line clamped in. I ordered the crimper from my tool guy for the Oetiker clamps and next time I'm in there I will crimp clamps on.
[IMG][/IMG]

[mr_dave]

Thanks for the pics!

What are you guys using for hose? I'm assuming you'd need to use the high pressure fuel injection stuff? 5/16in?

[SteelyS6]

Yes 5/16 rubber fuel line, stuff I got was rated for 3.7 Bar I believe, I can confirm when I get to work.

[julex]

I have some Oetiker clamps but don't have the pliers and the size I do have is a little big. think I bought them for a P/S cooler line fix. Probably going to use proper fuel line clamps, not a regular gear clamp. What pressure does this line see anyways?

whatever your FPR is which would probably be 4bar, 60psi. It is not about the ability to hold pressure but resistance to vibration and temperature swings that undo worm clamps. T-bolt fuel line clamp would work here though!

[SteelyS6]

Well line was good overnight, drove to work, 3 hrs later I check it after being warm and then cooling off and its leaking again, seems to be at the metal fitting that screws onto fuel rail.

I'm wondering if the metal fitting is cracked. Will be reassessing my options today. Frustrated obviously.

[julex]

Well line was good overnight, drove to work, 3 hrs later I check it after being warm and then cooling off and its leaking again, seems to be at the metal fitting that screws onto fuel rail.

I'm wondering if the metal fitting is cracked. Will be reassessing my options today. Frustrated obviously.

this fitting in notorious to leak in very low temps. You're not the first, or the last. Again, simply carefully dremel the outer jacket off and put a clamp on. Alternatively, if you have access to some crimping equipment, you could simply crimp the outer jacket onto the line and probably be good for next 10 years.

[SteelyS6]

That's what I did, salvaged the fitting by cutting off the crimp and then clamped a new hose onto the barb that was remaining. I suspect there is something not right on the barb or fitting itself.

[SteelyS6]

The OE is a molded hose, you can also buy the straight hose (I think for a B6?, double check the part number, 4B0201541C) and trim it to length.

Broke down and bought this line this morning, will report back on results and fitment once I have it. Thanks for the part#