Coolant tube-check this if you are replacing other coolant parts!

jdulle

Veteran Member
Joined
Feb 4, 2017
Location
Ithaca, NY
TDI
96 B4, 97 B4
My 97 B4 sedan lost a bunch of coolant, when I checked it out it was leaking from the metal tube that runs around the driver's side of the engine, toward heater core hoses. Perhaps you all have heard rumors that these rust out...it was true in my case, totally rotted out where the two back hoses attach. I would recommend those that live in salty or humid environments, or don't replace the coolant too often should replace this. There was noticeable swelling for several years around the spot where it failed, so if you are watching carefully you can catch it. I bought a replacement aftermarket one that is for an aaz engine, it is partially installed and the front bolt in, not sure if it will quite fit the rear bolt location. It's not going to hold the wiring connector for the IP like the original one, but I'll figure something out. One more thing to check to reduce the risk of being stranded or blowing a head gasket.
 

Starion_slider

Well-known member
Joined
Dec 28, 2018
Location
CT.
TDI
1996 B4 sedan
If you look around you can still find the one with the fork to hold the IP plug. I stock up on parts and I have both types. The one id parts sells dose not have the plug mount. I found the other on ebay. Mine was leaking last summer so I replaced it when I replaced the leaking o-ring at the coolant flange on end of head where the coolant GP’s are. Original coolant pipe lasted 455k .

heres the link to one with the IP plug mount.
Pipe
 

jdulle

Veteran Member
Joined
Feb 4, 2017
Location
Ithaca, NY
TDI
96 B4, 97 B4
Nice! I don't know if there will be a next time for me, but I'll keep that in mind. I had to do the o ring on the flange on the front of the head, but did not really think about the one on the side. I should probably buy the o ring now.
 

Starion_slider

Well-known member
Joined
Dec 28, 2018
Location
CT.
TDI
1996 B4 sedan
Nice! I don't know if there will be a next time for me, but I'll keep that in mind. I had to do the o ring on the flange on the front of the head, but did not really think about the one on the side. I should probably buy the o ring now.
Mines gotta last another 22 yrs until i retire so I tend to gather spare parts.
 

Starion_slider

Well-known member
Joined
Dec 28, 2018
Location
CT.
TDI
1996 B4 sedan
You can retire. The TDI shouldn't.
I agree. My passat is one of those cars where if I hit the lotto tommorow I would honestly just keep driving. I actually love the car. Even with its quirks I still say i love this car even after almost 13yrs. Its kinda a game to me to just prove I can keep it alive forever.
 

Lug_Nut

TDIClub Enthusiast, Pre-Forum Veteran Member
Joined
Jun 20, 1998
Location
Sterling, MA. USA
TDI
2015 GSW 6M in S trim the other oil burners: 1967 two stroke Sonett 1988 Bolens DGT1700
Were these NY and CT cars bought new and then driven in winters in the N.E. region?
Were they bought used from southern US states?
I'm incredible that these were original coolant pipes that only recently rotted through. Mine failed before the cars were 10 years old.
 

Starion_slider

Well-known member
Joined
Dec 28, 2018
Location
CT.
TDI
1996 B4 sedan
Were these NY and CT cars bought new and then driven in winters in the N.E. region?
Were they bought used from southern US states?
I'm incredible that these were original coolant pipes that only recently rotted through. Mine failed before the cars were 10 years old.
My car originally came from PA from what I’ve seen. Been here in CT as my normal daily. The pipe looked like it was on its last leg 10yrs ago but I just let it ride. I’ve replaced floor pans front to back, 3 doors, most of a rear quarter and all brake lines and every other part that could rot off the damn thing. I just fix it and keep driving. I actually just got around to fixing my big oil leak I’ve had since summer time. Probably 5yrs ago I noticed the crimps on the flex hose for the turbo oil return were literally rotted right off so I just slapped some worm gear clamps on it for a “temporarily permanent fix”. Then this past summer it started leaking and i just ignored it until I had some time. It rotted just above the clamp and started pissing out of a hole. Most would replace the entire line but my turbo is original 460k and its like rotted to death missing 2 of the clamps that hold the center section into the exhaust housing and the oil drain line bolts are almost entirely pitted and rotted to death so I had to adapt and overcome. My new temporary permanent fix was to get up there with my die grinder and lop off the pipe just below the flange and then on bottom where banjo bolt is. Clamped a piece of push lok line in there and we are good to go again. No leaks. When the turbo finally bites the dust or something else happens I will just replace everything anyways.
 

jdulle

Veteran Member
Joined
Feb 4, 2017
Location
Ithaca, NY
TDI
96 B4, 97 B4
I think mine was originally from MD, but spent at least 10 years commuting to NYC from southern Mass/conn, and now 8 years here in central NY state. It could have been replaced at some point, but I am guessing it was original. I think the car was garaged for quite a bit of its life, and probably had regular coolant changes. I think these rot from the inside out, if the coolant doesn't get changed, as well as rusting on the outside from salt spray and humidity.
 
Top