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Fatigue failure in external pump fuel line
I spent the morning under the ur-quattro again.
At least part of my fuel system pressure loss was due to what appears to be a
fatigue failure in the semi-rigid fuel line between the (external) fuel pump
and the pressure accumulator. I was amazed to find that this line, which
carries the full ex-pump pressure of 6+ bar, is simply a plastic pipe with no
reinforcement or protection of any kind. Anyway, it failed by cracking on the
upper side where the plastic pipe is fitted over (shrunk on?) the banjo bolt.
This is Audi part # 857 201 220, wrongly identified on VAG UK's computer system
as "PUMP BRKT". Obtaining a replacement was not easy, as VAG's computers kept
printing picking slips and dispatch labels saying "PUMP BRKT" and everyone who
handled it thought they had picked the wrong thing and sent it back.
Committee Member, UK Audi [ur-]quattro Owners Club