Custom injector lines?

[motomike33y]

Looking for a source to get custom injector lines for my vanagon.  has 1.9 bottom end, and 1.6 mechanical head and regular 1.6 IP.  result is that stock  lines are about an inch too short to fit correctly.  I've bent them to fit, but lose the ability to fasten lines together to lessen vibration.  Also moving the timing w/out loosening the lines stressed them.  as a result after about a thousand miles, I've broken the tip off two lines at the injector.  vanagon then runs very poorly on 3 cylinders.  Are there any sort of flexible custom lines available, similar to braided lines for brakes?  Some type of bending tools that would allow me to utilize stock lines but rebend them to fit?  suggestions?  thanks.

[theman53]

I believe and someone more smarter than me could tell you, but, As long as the injector lines are the same length for all of them it should be ok. I would only want something like the HYDRAULIC line that is factory as they handle over 1,500psi of diesel in them. If they are considerably longer than stock the timing maybe needing to be set more advanced...just guessing.

[motomike33y]

My problem lies with the stress/vibration resulting from my inartful bending of the regular lines to fit.  I can't continue to replace lines every 1000 miles, or I'll run out of my stock of surplus lines.  Bending new to fit could work, but I lack the appropriate tools and supplier, or getting flexible lines of the appropriate length would work, if I had a supplier.  thanks.

[theman53]

If you could mock up a set like you already have and take it to a hydrualic shop they should be able to help you out. You could even mock up some with copper or nylon tubing to get it perfect. I just know that the braided stainless probably won't take it. I got the highest rated one weatherhead had and I think it was only rated to 1800psi at 350 degrees or something like that.
Would the 1.9 lines work? I just reread and it looks like you are trying the 1.6 only?

[motomike33y]

I've got the 1.6 pump/head mated to 1.9(AAZ?) shortblock.  The result is that the offset is about an inch more than the stock lines.  didn't realize I was having a problem until one broke and blew fuel for 40 miles as I was drivng home wondering about the smell and then noticed the film on my back window(I was driving at dusk-night time.   Replaced it, then 2nd one broke identically about 50 miles later.  Then I realized the problem wasn't necessarily just w/one line/coupling.  Looking for ideas.  I don't have access to any TDI lines right now, so don't know about their fit.  my brother may have some, so I can check this weekend with him.

[theman53]

What lines are you using now, that is what I wanted to know. 1" too short means what? Are they are 1" from meeting the injector, or they are meeting it 1" down the injector? One or the other set of lines should work depending on which way it is.

[motomike33y]

sorry.  I'm using stock lines from my various 80's vintage 1.6 NA's.  I've unbent/bent them somewhat individually to reach the appropriate injector.  the stock bend results in about an inch short from injector to pump fitting. My efforts have has resulted in 4 individual lines that aren't fastened together so each is vibrating/etc. on its own.  If I take the standard 4 lines/fastened together for rabbit, place them on injectors, they are about an inch away from the respective fitting on the pump.  lines have enough length to reach, if they had different bend.  sorry I'm unable technically to take and send pics.

[motomike33y]

to clarify, if the pump was an inch closer to the block/head, then the lines would hook up.

[theman53]

try getting some aaz lines

[motomike33y]

good thought, but I'd like to verify they'd fit.  First I have to locate some, will try Parts Place, they may have some info.  That was where I'd gotten the shortblock years ago.

[Powered by Spearco]

AAZ lines won't work either, if your using the 1.6 pump on a AAZ block. I think if you use 1.6 injectors with your setup, the 1.6 NA line might make it.
I ran into the same problems when I was trying to use AAZ lines with 1.9 injectors on a 1.6 long block. But the delivery valves are shorter on the 1.6 pumps than the 1.9 ones.

[motomike33y]

Thanks.  I am using 1.6 injectors, and 1.6 lines, but am having breakage problems due to having to rebend the lines to lengthen them.  Maybe I'm just not careful enough-I will be trying to individually fit the lines, but am not optimistic.

[motomike33y]

Parts Place has none, so they can't even check for me.  Anyone got a set of used AAZ lines they can compare to stock 1.6 or sell me inexpensively or swap for some 1.6 lines?

[bajacalal]

A shop that deals specifically with diesel injection systems or heavy duty stuff may be able to fabricate some lines for you.