Need to replace braided fuel, vacuum hoses, etc. What length? Where to buy?

Phi1osopher

Veteran Member
Joined
Jul 31, 2019
Location
Austin, TX
TDI
'96 B4V TDI Passat Wagon
Need to replace braided fuel, vacuum hoses, etc? Here's what to order!

1996 Passat (B4V) TDI wagon:
I noticed a dribble trail on the ground behind my car. I discovered I had a cracked diesel return fuel line leaking enough to leave a trail on the ground. ACK! I replaced the return lines some cheap, clear "chainsaw" 1/8” fuel line from the nearest auto parts store, so I could at least get home without leaking any more fuel.. (Curiously, I inspected and removed my old cabin air filter 2 days ago. It was so ancient it instantly fell apart in my hands. It was utterly, completely clogged, and after removing it I began to notice a slight diesel smell inside the car. Maybe a coincidence, maybe not..)
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I recognize this crappy fuel hose is a temporary solution, but it made me remember I want to replace all the cloth braided return fuel and vacuum hoses, along with any others I am not thinking of right now...
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After extensive forum searching, I was hoping to find a cheat sheet with the required lengths, size, and a suggestion as to where all this braided hose stuff could be purchased.. it seems measuring would take quite a while, and the effort would further mess up the current degraded old ones.
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I'd prefer to replace with similar to OEM: colored, braided vacuum and return fuel hose. I'm also open to using color coded silicone or PTFE.
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Any suggestions? Does anyone sell a replacement "kit" where can get it all at once?
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Thanks!
EDIT, Here's what to order:
Quick Order Summary. It's all 1/8" or 3.5mm ID, except EGR (it's 5mm) :
BLACK 5mm ID = ~3.5'
BLACK 3.5mm = ~10'
BLUE 3.5mm = 5'
RED 3.5mm = 5'
CLEAR diesel return line, 3.5mm(Tygon) = 2'
Hose Clamps (1/4"/ 7mm) =9

Black 3.5mm pressure/vacuum hoses: ~10'
From Vacuum Pump:
#1 - (climate control)behind battery -- 3' +??? (through firewall, under dash, maybe 4'?)
#2 - to firewall/EGR -- 2',3.5'
From "Boost Pressure Transducer" to intake @ PVC pipe
#1 - 3'
Black 5mm From Manifold to ECU (boost pressure)
#1 - 3.5' 5mm

BLUE 3.5mm pressure/vacuum hose: 5'
From "Boost Pressure Transducer" to "Boost Pressure Valve' (on Turbo)
#1 - 5'

RED 3.5mm pressure/ vacuum hose: 5'
From Turbo to Boost Press' Transducer:
#1 - 5'
 
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Mozambiquer

Vendor , w/Business number
Joined
Mar 21, 2015
Location
Versailles Missouri
TDI
2004 VW Touareg V10 TDI, 2012 Audi Q7 V6 TDI, 1998 VW Jetta TDI. 1982 VW Rabbit pickup, 2001 VW Jetta TDI, 2005 VW Passat wagon TDI X3, 2001 VW golf TDI, 1980 VW rabbit pickup,
They sell it at O'Reillys or other parts stores. You have to cut to length. I got some from a VW dealership before, and it also you had to just cut to length.

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Mongler98

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Joined
Mar 23, 2011
Location
COLORADO (SE of Denver)
TDI
98 Jetta TDI AHU 1.9L (944 TDI swap in progress) I moved so now i got nothing but an AHU in a garage on a pallet.
The silicone hose I got from Amazon works freaking crazy good.
 

Phi1osopher

Veteran Member
Joined
Jul 31, 2019
Location
Austin, TX
TDI
'96 B4V TDI Passat Wagon
12'

I went ahead and measured all the under the hood vacuum lines/ boost pressure hoses and diesel return hoses. I did not take apart the dash to measure the black one that goes through the firewall to the climate controls.. these measurements are quick estimates with a tape measure, rounding up. the all appear to be 3.5mm or 1/8" inside diameter. There are 9 locking clips, and if you should order them according to the outside diameter of the hose you are purchasing. The OEM hose clamps are the permanently installed crimp-style, and something similar probably probably is best...

Quick Order Summary: BLACK = ~12'; BLUE = 5'; RED = 5'; CLEAR (PTFE) = 2'; Hose Clamps =9


Return diesel fuel hose 3.5mm BLACK or CLEAR PTFE:
about - 2'

Black 3.5mm pressure/vacuum hoses: ~12'
From Vacuum Pump:
#1 - (climate control)behind battery -- 3' +??? (through firewall, under dash, maybe 4'?)
#2 - to firewall/EGR -- 2',3.5'
From Manifold to ECU (boost pressure)
#1 - 3.5'
From "Boost Pressure Transducer" to intake @ PVC pipe
#1 - 3'

BLUE 3.5mm pressure/vacuum hose: 5'
From "Boost Pressure Transducer" to "Boost Pressure Valve' (on Turbo)
#1 - 5'

RED 3,5mm pressure/ vacuum hose: 5'
From Turbo to Boost Press' Transducer:
#1 - 5'
 
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vwxyzero

Veteran Member
Joined
Jul 12, 2004
Location
Los Angeles, CA
TDI
'96 Passat Sedan, '96 TDI Passat Wagon, & Jetta Sedan, '83 Turbodiesel (IDI)
Return diesel fuel hose 3.5mm BLACK or CLEAR PTFE: about - 2'
Phi1osopher, this is the best thing you can use for the return fuel lines:
https://www.mcmaster.com/viton-fluoroelastomer-tubing

The OEM hose clamps aren't permanent, but 'some' might need replacing.

What's with all the colors? Do it right once and you'll most likely never need to know what color a line is.


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Phi1osopher

Veteran Member
Joined
Jul 31, 2019
Location
Austin, TX
TDI
'96 B4V TDI Passat Wagon
Phi1osopher, this is the best thing you can use for the return fuel lines:
https://www.mcmaster.com/viton-fluoroelastomer-tubing

The OEM hose clamps aren't permanent, but 'some' might need replacing.

What's with all the colors? Do it right once and you'll most likely never need to know what color a line is.
you made me giggle.

thanks for the fuel line recommendation.

I like the OEM colors. They're pretty!

In my opinion, these crimp-style clamps are one-time use, designed to be installed and not fiddle-faddled with afterwards.... Maybe permanent was the incorrect word choice.
 

vwxyzero

Veteran Member
Joined
Jul 12, 2004
Location
Los Angeles, CA
TDI
'96 Passat Sedan, '96 TDI Passat Wagon, & Jetta Sedan, '83 Turbodiesel (IDI)
you made me giggle.

thanks for the fuel line recommendation.

I like the OEM colors. They're pretty!

In my opinion, these crimp-style clamps are one-time use, designed to be installed and not fiddle-faddled with afterwards.... Maybe permanent was the incorrect word choice.
LOL


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Abacus

That helpful B4 guy
Joined
Nov 10, 2007
Location
Relocated from Maine to Dewey, AZ
TDI
Only the B4V left
The colors look nice, are easy to trace out, and the same price, so why not.

The clamps are ‘one-time use’.

Get the crimpers with the side, you’ll use them more since many of the places aren’t very accessible.

FYI, if your EGR is still hooked up, it's a larger diameter, 5mm.
 
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