josh8loop
Veteran Member
- Joined
- Sep 15, 2009
- Location
- Vero Beach, Fl.
- TDI
- 2002 VW Jetta TDI Manual(performed 01M to 5-speed swap) - 183,000 miles and climbing!
Fellas,
Quite a while back I had issues with the dreaded air-in leakage effecting startability of my TDI. At that time I had the 01M transmission and from what I understand the automatic transmission equipt vehicles didn't offer the clear fuel lines from the fuel filter. Since my fuel lines were in bad shape, and I needed a clear section of tubing to help troubleshoot my air-in leakage issue I decided to come up with a solution that would work well long term and be temperature and chemically compatible. Here is what I came up with:
Above: I visited the junk yard and found a 2000-2004 Jetta gasser and extracted some of the fuel system quick disconnect fittings. At least two are needed but if you are like me and break one then it would be better to have three! Pay no attention to the ball snap-it's for another project
..
Below: Once you have the quick disconnect fittings the old plastic and rubber lines can be GENTLY removed. One end of the male quick disconnect has an O ring so be cautious!
Above: Once your disconnect pieces are prepared it's time to find some clear Teflon tubing. McMaster Carr has some Teflon PFA Clear tubing that is 8mm(.300-.315") ID and 10mm OD that will work well. The ID is the MOST CRITICAL dimension since it is what will seal on the O ring and stretch around the retaining hose barb. The product code number is: 5733K78 and the link is:
http://www.mcmaster.com/#5733K78
You will need at least 4 inches of it. While at the junk yard look for some stainless steel hose clamps on fuel and vacuum lines. Some types are reuseable and you can use a pair of piers to gently slide the SS clip ring apart and it will release. The clamps aren't necessary but I like the look and also knowing that it won't come apart. The clamp shown in the picture isn't in it's proper position which would be directly over top of the O ring on the male section of the quick disconnect.
..
Below: Here it is connected to the vehicle. I used some 5/16" ID "Weatherhead" diesel rated hose from NAPA since it has a stock-like cloth braid appearance.
I also got tired of dealing with replacing the rubber fuel lines connecting the injectors to the IP. I used some Teflon tubing on that too since it will take the heat and give me a way to see if my air is leaking through those areas! I used some smaller diameter SS clips on that also. I will take some measurements and see what diameter tubing would be needed for those line aswell:
Measuring the fuel injector nipples it looks like 4mm Teflon PFA Clear tubing will work. The 4mm stuff will have to stretch 1.5mm to go over the number 3 injectors barbs but is doable. Here is the McMaster link for it:
http://www.mcmaster.com/#5733K54
The total length needed for the fuel injector return lines will be minimum of 3 feet. That gives you 3.5" between each of the three injectors and then gives you about two feet for the return portion to the IP. By the way none of the line replacements interfere with the engine cover so that's not an issue either. I've had my clear Teflon fuel line quick disconnect assembly on for a couple years with absolutely no issues. I started converting the fuel injector return line a year ago and just finished replacing the last rubber piece of fuel injector tubing(piece between the last fuel injector and the IP a few weeks ago after I had a major blowout there which resulted in an engine/clutch that was completely doused with diesel! Now with the Teflon tubing I have no worries of fuel injector line leakage and can remove it from my preventative maintenance list. I really like the ability to see if there is air getting into the lines easily-this mod has removed a large percentage of where air intrusion issues actually happen.
Quite a while back I had issues with the dreaded air-in leakage effecting startability of my TDI. At that time I had the 01M transmission and from what I understand the automatic transmission equipt vehicles didn't offer the clear fuel lines from the fuel filter. Since my fuel lines were in bad shape, and I needed a clear section of tubing to help troubleshoot my air-in leakage issue I decided to come up with a solution that would work well long term and be temperature and chemically compatible. Here is what I came up with:
Above: I visited the junk yard and found a 2000-2004 Jetta gasser and extracted some of the fuel system quick disconnect fittings. At least two are needed but if you are like me and break one then it would be better to have three! Pay no attention to the ball snap-it's for another project
..
Below: Once you have the quick disconnect fittings the old plastic and rubber lines can be GENTLY removed. One end of the male quick disconnect has an O ring so be cautious!
Above: Once your disconnect pieces are prepared it's time to find some clear Teflon tubing. McMaster Carr has some Teflon PFA Clear tubing that is 8mm(.300-.315") ID and 10mm OD that will work well. The ID is the MOST CRITICAL dimension since it is what will seal on the O ring and stretch around the retaining hose barb. The product code number is: 5733K78 and the link is:
http://www.mcmaster.com/#5733K78
You will need at least 4 inches of it. While at the junk yard look for some stainless steel hose clamps on fuel and vacuum lines. Some types are reuseable and you can use a pair of piers to gently slide the SS clip ring apart and it will release. The clamps aren't necessary but I like the look and also knowing that it won't come apart. The clamp shown in the picture isn't in it's proper position which would be directly over top of the O ring on the male section of the quick disconnect.
..
Below: Here it is connected to the vehicle. I used some 5/16" ID "Weatherhead" diesel rated hose from NAPA since it has a stock-like cloth braid appearance.
I also got tired of dealing with replacing the rubber fuel lines connecting the injectors to the IP. I used some Teflon tubing on that too since it will take the heat and give me a way to see if my air is leaking through those areas! I used some smaller diameter SS clips on that also. I will take some measurements and see what diameter tubing would be needed for those line aswell:
Measuring the fuel injector nipples it looks like 4mm Teflon PFA Clear tubing will work. The 4mm stuff will have to stretch 1.5mm to go over the number 3 injectors barbs but is doable. Here is the McMaster link for it:
http://www.mcmaster.com/#5733K54
The total length needed for the fuel injector return lines will be minimum of 3 feet. That gives you 3.5" between each of the three injectors and then gives you about two feet for the return portion to the IP. By the way none of the line replacements interfere with the engine cover so that's not an issue either. I've had my clear Teflon fuel line quick disconnect assembly on for a couple years with absolutely no issues. I started converting the fuel injector return line a year ago and just finished replacing the last rubber piece of fuel injector tubing(piece between the last fuel injector and the IP a few weeks ago after I had a major blowout there which resulted in an engine/clutch that was completely doused with diesel! Now with the Teflon tubing I have no worries of fuel injector line leakage and can remove it from my preventative maintenance list. I really like the ability to see if there is air getting into the lines easily-this mod has removed a large percentage of where air intrusion issues actually happen.
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