Phi1osopher
Veteran Member
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..)
.
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...
.
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.
.
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.
.
Any suggestions? Does anyone sell a replacement "kit" where can get it all at once?
.
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'
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..)
.
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...
.
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.
.
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.
.
Any suggestions? Does anyone sell a replacement "kit" where can get it all at once?
.
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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