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VW MKIV-A4 TDIs (VE and PD) This is a general discussion about A4/MkIV Jetta (99.5-~2005), Golf(99.5-2006), and New Beetle(98-2006). Both VE and PD engines are covered here.

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Old July 5th, 2013, 09:03   #16
josh8loop
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Originally Posted by darkscout View Post
I'm thinking of ordering enough to do all my lines. It seems flexible enough, any reason not to just do the whole system in this?

The Teflon lines I have added are working superbly. They are super clear and hold up to heat and chemicals really well. Actually Teflon is inert to most chemicals and can take extreme temperatures. It can be a bit expensive but just doing your inter-injector lines, your return line from the injectors to the IP, and perhaps from the fuel filter to IP wouldn't hurt a bit. One thing to watch out for is that some of the lines they specify as "clear" aren't really that clear so make sure you are certain before you get it ordered. The tubing and SS clamps I specified above should work well.
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2002 VW Jetta TDI 5-speed(completed 01M-5-speed swap at 155K miles) 60+ MPG City.
Experimenting with the "Hybrid" 205 Deg F T-stat:
http://forums.tdiclub.com/showthread.php?t=306799&page=4
Now have Nokian Entyre Low RR tires!
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Old July 10th, 2013, 18:49   #17
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Old September 12th, 2013, 17:52   #18
drklawz
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Default Any updates?

Hey! - Any updates? I've been thinking about doing this swap while I have the injectors out.

MB
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Old September 29th, 2013, 13:36   #19
josh8loop
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Hey! - Any updates? I've been thinking about doing this swap while I have the injectors out.

MB

Yes, actually working perfectly. So well in fact, I'm considering doing the same when I replace fuel injector return lines on the Wifes 2005 E320 CDI
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2002 VW Jetta TDI 5-speed(completed 01M-5-speed swap at 155K miles) 60+ MPG City.
Experimenting with the "Hybrid" 205 Deg F T-stat:
http://forums.tdiclub.com/showthread.php?t=306799&page=4
Now have Nokian Entyre Low RR tires!
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Old February 3rd, 2014, 01:13   #20
Bjar
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I have a few questions about the pinch clamps,

http://www.mcmaster.com/#52545K38

What tool do you use to crimp these? Can you use the same tool that you would use for Pex plumbing cinch clamps?
http://www.pexuniverse.com/store/cat...ex-clamp-tools
The pinch clamps you used look almost exactly the same as Pex cinch clamps, just smaller.

Or is this tool from McMaster-Carr the only appropriate tool?:
http://www.mcmaster.com/#pinch-clamp-pincers/=qj3by7

Would there ever be a need to remove the Teflon return hoses, and if so, how in the world do you take the pinch clamps off? Can you safely twist them off with vise-grips?

Last edited by Bjar; February 3rd, 2014 at 01:20. Reason: Adding hyperlinks
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Old February 3rd, 2014, 13:00   #21
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How is that so CLEAN!? o.0
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Old March 1st, 2014, 13:48   #22
MrSafety
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Default A4 Jetta TDI Clear Teflon Fuel Line/Injector Return Line Upgrade...

josh8loop,
First let me compliment you for this THREAD and its many quality closeup photos!

My question(s) have to do with the Quick-Disconnect "elbows" you show:
Q1 - Are these OE parts?
Q2 - If not can you tell me your source for these ?

I'm working on my Son's 2002 TDI trying to replace the two 8mm fuel lines between the fuel filter and the rigid fuel lines coming up from below into the engine compartment... the ones that have quick-disconnect "elbows" that clip to the rigid fuel lines!

I purchased OE part 1J130295/A/D/E for only this elbow fitting... only to find it is too small to fit on the end of the rigid lines... so I'm mainly looking for an alternative source for these OE fittings on which I believe the internal O-rings are worn failed and now allow air to be sucked into one or both the fuel lines... a problem I'm sure you are all too familiar with!

I like your original project's intent to install a clear section of fuel line just prior to the IP and and will complete the same on his 2002 TDI soon!
Regards... and thanks again for you QUALITY POST !,
Sam Ross
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Old March 2nd, 2014, 20:12   #23
dremd
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Wow.
Wish I had seen this before my swap. I would have done it then for sure.
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Old June 5th, 2014, 09:08   #24
josh8loop
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Quote:
Originally Posted by Bjar View Post
I have a few questions about the pinch clamps,

http://www.mcmaster.com/#52545K38

What tool do you use to crimp these? Can you use the same tool that you would use for Pex plumbing cinch clamps?
http://www.pexuniverse.com/store/cat...ex-clamp-tools
The pinch clamps you used look almost exactly the same as Pex cinch clamps, just smaller.

Or is this tool from McMaster-Carr the only appropriate tool?:
http://www.mcmaster.com/#pinch-clamp-pincers/=qj3by7

Would there ever be a need to remove the Teflon return hoses, and if so, how in the world do you take the pinch clamps off? Can you safely twist them off with vise-grips?

Yes, you should be able to use that tool or just use some end cutter wire cutters to crimp them like I do. Should you need to remove anything you can either gently wiggle the teflon hose/clamp assembly off the barb or preferably cut the SS clamp off and replace it later.
__________________
2002 VW Jetta TDI 5-speed(completed 01M-5-speed swap at 155K miles) 60+ MPG City.
Experimenting with the "Hybrid" 205 Deg F T-stat:
http://forums.tdiclub.com/showthread.php?t=306799&page=4
Now have Nokian Entyre Low RR tires!
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Old June 5th, 2014, 09:21   #25
josh8loop
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Quote:
Originally Posted by MrSafety View Post
josh8loop,
First let me compliment you for this THREAD and its many quality closeup photos!

My question(s) have to do with the Quick-Disconnect "elbows" you show:
Q1 - Are these OE parts?
Q2 - If not can you tell me your source for these ?

I'm working on my Son's 2002 TDI trying to replace the two 8mm fuel lines between the fuel filter and the rigid fuel lines coming up from below into the engine compartment... the ones that have quick-disconnect "elbows" that clip to the rigid fuel lines!

I purchased OE part 1J130295/A/D/E for only this elbow fitting... only to find it is too small to fit on the end of the rigid lines... so I'm mainly looking for an alternative source for these OE fittings on which I believe the internal O-rings are worn failed and now allow air to be sucked into one or both the fuel lines... a problem I'm sure you are all too familiar with!

I like your original project's intent to install a clear section of fuel line just prior to the IP and and will complete the same on his 2002 TDI soon!
Regards... and thanks again for you QUALITY POST !,
Sam Ross

Yes, these are OE components on the quick disconnect elbows. Review post #1 for my source of those. Remember those quick disconnect elbows have two O rings in them and a brass separator ring. Those O rings can be replaced with Viton O rings. The O rings are difficult to get out and you need to be careful not to pick them too hard with a pick tool otherwise you will damage the internal sealing surfaces. Also getting the brass separator ring in the correct spot can be difficult too. Purchase some Hylomar sealant like this from Autohaus AZ next time you place an order there and coat the mating/sealing surfaces of all fuel connections:

https://www.autohausaz.com/search/pr...mber=559526007

I've used that stuff for all my fuel line connections-fuel filter Tee included and the results have been very pleasing. The Hylomar is also diesel and related fuel additive compatible.
__________________
2002 VW Jetta TDI 5-speed(completed 01M-5-speed swap at 155K miles) 60+ MPG City.
Experimenting with the "Hybrid" 205 Deg F T-stat:
http://forums.tdiclub.com/showthread.php?t=306799&page=4
Now have Nokian Entyre Low RR tires!
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Old June 21st, 2014, 18:40   #26
MAXRPM
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nice write up need to do mine sick and tired of replacing the oem injectors fuel lines. got to get this
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Old October 15th, 2014, 08:32   #27
josh8loop
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Quote:
Originally Posted by josh8loop View Post
Yes, actually working perfectly. So well in fact, I'm considering doing the same when I replace fuel injector return lines on the Wifes 2005 E320 CDI

Just wanted to update. I have finished doing this on my wifes 2005 E320 CDI about 4 months ago. It looks really nice and works extremely well. My ALH with this mod is still working and looking great as well which is to be expected since it's a permanent fix. Just wanted to post feedback after the few years that I have had this mod in service
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2002 VW Jetta TDI 5-speed(completed 01M-5-speed swap at 155K miles) 60+ MPG City.
Experimenting with the "Hybrid" 205 Deg F T-stat:
http://forums.tdiclub.com/showthread.php?t=306799&page=4
Now have Nokian Entyre Low RR tires!
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Old August 25th, 2016, 14:48   #28
panthers89fan90
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I hate to dig up a grave here, but had a few questions.

I see you did the lines from the hard line to the fuel filter as well. What clamps do you use for the hard line portion of the fuel hose?

Also, I don't see an o-ring on the fuel quick disconnects. Where is this o-ring located?
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Old February 9th, 2017, 19:49   #29
josh8loop
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Originally Posted by panthers89fan90 View Post
I hate to dig up a grave here, but had a few questions.

I see you did the lines from the hard line to the fuel filter as well. What clamps do you use for the hard line portion of the fuel hose?

Also, I don't see an o-ring on the fuel quick disconnects. Where is this o-ring located?


The spring clamps I used are the same stock clamps used on the rubber lines that go on the fuel filter. I believe I ended up picking up a bunch of them from another VW at the junk yard. Also, the O rings on the quick disconnect are buried inside the female part of the QD fitting. You have to gently use a dental pick to coerse them out. There are a couple different types of fittings however and the ones you have may be a bit different than mine.
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2002 VW Jetta TDI 5-speed(completed 01M-5-speed swap at 155K miles) 60+ MPG City.
Experimenting with the "Hybrid" 205 Deg F T-stat:
http://forums.tdiclub.com/showthread.php?t=306799&page=4
Now have Nokian Entyre Low RR tires!
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Old August 5th, 2017, 18:12   #30
Tsiah
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Any chance you can re-host the pictures for this?
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