New fuel lines for a Lehman 4D61

[smacksman]

My repair I made in Stuart last year to stop a leaking fuel line was not 100% successful.
As one 33 year old line was iffy I replaced the lot.

banjo4-detail.jpg

A company called Melville Equipment in Harvey across the Mississippi from Seabrook Harbor did a really good job.

They removed the old crimp part of the banjo fitting

banjo3-detail.jpg

and brazed on a new union.

banjo1-detail.jpg

banjo2-detail.jpg

Cost $153 including two taxes.
Now in future the fuel line can be easily replace and the banjo stays in place. OK, its doubled the number of joints to leak but at least it is now modern and replacable.

[kerrye]

Any idea what was under that original crimp? There's a similar fitting on my Westerbeke 42 and I was wondering just that the other day. On Mercedes cars, under the crimps are barbed fittings on which one can slide a fuel line and hose clamp. Good repair and not very pricey.

[smacksman]

Not on these ones - just a smooth 1/4" copper pipe. That is why my repair in Stuart still leaked I think. I cut the crimp off to expose the pipe. No shoulder for the clamp to grip on. Of course it could have leaked because the hose was knackered anyway. I had three goes at a repair and in the end ran out of hose length so stuck with the final (98% success) attempt.
A previous owner had sort of come up with a kludge by fitting a 5/16" hose OVER the crimp and then squishing it up with a hose clip. It didn't leak (on the return line)
Roger

[kerrye]

Makes me think I should pick up a few of these:

http://www.ebay.com/itm/Metric-BANJO-x- ... 0778348867

[smacksman]

Typical of the motor industry - these banjos on a French engine were Imperial, or Standard as you call it in the States, 1/2" except for one which was a tad bigger.
I did find a supplier of banjos in the States but not one did the double 90 degree banjo on the primary filter return line. This of course had to be the banjo that I butchered in Stuart!

[Sprig1]

Hi smacksman glad you made it back. I found the fuel hoses at a hydralic hose repair store. They even had coast guard approved fuel hoses. That's my next project get the motor running. Also check under your cooling line it is probably rubbing on your injector lines your pipe runs the same way as mine.

[smacksman]

Hi Sprig1 - yep it's good to be back spending money on the boat!
As you say, the return line from the pump threads its way under the injector pipes. As the original pipe was externally wire braided I would have been more worried about the injector line being chafed. Those pipes cost real money! I had the replacement made a tad longer and plan to run it outside.
Hunkered down in the cabin at the moment as the mother of all thunderstorms rage outside. A good feeling to be snug and dry.

[Sprig1]

Hi smacksman no I was talking about the water cooling line coming back from the thermostat rubbing on the steel injector lines. One of mine was almost rubbed through. You have to look under neith the cooling line. I didn't see it until I replaced all my cooling hoses.

[smacksman]

Ah. I understand now. Yes, chafe is an expensive hazard.

I've run the lines mostly outside now. It would make the statistical overall width of the engine bigger on the manufacturers data sheet!

overhead.jpg

pretty' blue for a boy' new fuel lines

feedpump1.jpg

Fuel pump. Loosen the fixing allen bolts to get the banjo bolt off.

primary-filter.jpg

Primary fuel filter and double banjo difficult to source.

injector pump1.jpg

bleed the system

[kerrye]

Could you stack two single banjo bolts in place of the single double bolt?

[smacksman]

I guess you could with a double length banjo bolt. I suppose they make such a beast?

[kerrye]

Yes. I didn't know they existed until I saw your problem. https://www.belmetric.com/double-banjo- ... -1041_928/

[smacksman]

Splashed three days after bleeding and the engine started first time.
Kept the revs up for a few seconds as she ran a bit rough as the last of the air bubbles were blown through and then she ran as sweet as a nut. Noticeably quieter with the new air filter on.
No leaks. Job done.

[sail149]

Glad you got you fuel lines sorted.
After kerrye's link I looked for banjo fitting and looks like you can buy ready made fittings with threads. Used for brake lines and fuel lines on cars.
http://www.jegs.com/webapp/wcs/stores/s ... Term=Banjo
These are 'imperial' ...not sure if we need metric or imp..?
Warren

[smacksman]

A good link Warren, but you can see from the multitude of options my quandry for someone who wants a quick job so I can get going in a few days. It turned out they were Imperial which is odd for a French engine. And one banjo was a bit bigger than the others - maybe metric.
I left the job to the professionals - gave the old lines to them - picked them up an hour later and paid top dollar. Fair for me.