924Board.org

[Mudd]

I removed my wur and cleaned it. I notice when I was putting it back on that the upper or larger banjo bolt did not have a washer on it. Don,t know if if had one on it when I took it off or if I lost it. I put a washer that I had laying around and put it back on the car. When I started the car gas was pouring out of the banjo bolt connection. My question is does this fitting require a special washer or what.
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1978 924
1987 944

[scm924s]

All fuel lines with banjo bolts need copper or alloy crush washers to seal the joints top and bottom. Steel washers are useless and dangerous.
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1984 n/a Ruby Red Metallic
1988 924S Guards red- sold
1986 924S Guards Red - sold
1984 n/a Black - sold
1980 n/a Le Mans#1 - sold
1980 n/a Le Mans#2- sold
1977 Martini - sold

[Mudd]

One more question, is it necessary to put a washer on both sides of the banjo fitting, two on each bolt.
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1978 924
1987 944

[Harm]

^yes.

They have to seal off both sides.

[Mudd]

I went to the car parts place and they sold me copper washers that he said are the same thing as fuel crush washers. Put one on each side of the banjo bolt, tighten down good, started the car and I have gas all over my garage. Gas was pouring out and spraying straight up under pressure. Someone please guide me to the correct washers for this application.
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1978 924
1987 944

[fiat22turbo]

Tighten them more. They need to crush to work. You may need to anneal them to get them to seal, but try torquing it again.
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Stefan
1979 924 Carrera GTS (clone-ish)
1988 944 Turbo S (Silver Rose)

[Mudd]

Sorry to be such a dumb ass but what does anneal mean..
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1978 924
1987 944

[fiat22turbo]

Heat them up to soften them so they'll seal more easily. Google annealing copper to get an idea on the process.
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Stefan
1979 924 Carrera GTS (clone-ish)
1988 944 Turbo S (Silver Rose)

[ideola]

There are two different sized banjo fittings on the WUR, one is M10, one is M8. The M10 banjo bolt takes two 10x14 copper crush washers (part # 900.123.033.20); the M8 banjo bolt takes two 8x11.5 copper crush washers (part # 900.123.050.20). As noted above, there should be two crush washers for each and every banjo fitting in the fuel system, one on each side of the fitting that is secured by the banjo bolt.

The banjo fittings for the fuel system do not require that much torque for sealing when using the proper crush washers, and you should not need to anneal them, they should come ready-to-go. Tech spec booklet indicates 7 foot pounds for the M8 bolt and 10 foot pounds for the M10 bolt. If you torque more than that you could gall the washers causing them to leak, so it's possible you either under- OR over-torqued them.

It's also possible the parts store didn't give you correctly-sized washers, or washers that weren't intended as crush-style sealing rings. You can try using some blue locktite on the sealing rings to help with sealing, although I've only ever done this on oil fittings, not fuel fittings. Very few parts stores carry correct parts required for the high pressures of our CIS systems, so if they weren't intended for that purpose, they may not work.
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erstwhile owner of just about every 924 variant ever made

[ThomasJoseph315]

you can get replacement fittings at the DMC website.

[Mudd]

Great information Ideola, thanks. I just ordered the correct washers from Pelican. Thanks for everybody's replies
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1978 924
1987 944

[Mudd]

I twisted the head off of the smaller banjo bolt on the WUR. Can someone tell me the part number for the WUR banjo bolts. Are these usually available at my local car parts place or do I need to buy them on line.
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1978 924
1987 944

[ideola]

The smaller one is 911.110.899.00
The larger one is 900.175.002.02

Unlikely you will find the correct parts at a FLAPS. Best to purchase the correct ones.
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erstwhile owner of just about every 924 variant ever made