Formed Fuel Line

[CantWrite]

Last summer rock fall came down the mtn just as i was going by and rolled under my car. I thought everything was fine but it pinched my fuel line. The leak is slowly getting worse and I would like to address it.

Does anyone have a source for the "Formed Fuel Line" that attaches to the shield/skid plate that also appears to serve as a fuel cooler, or do they have a spare they are willing to sell?

With the car at idle it drips every couple of minutes.

Options:

1. Replace (preferred)
2. Bypass and reinstall shield compromising the cooling aspect (may not matter in CO)
3. Other Ideas.......

Here is a horrible photo of what I am talking about. the piece is about 5 feet long.

fuel line.jpeg

• CantWrite
• Jun 25, 2024

Wet Fuel Lines.jpeg

• CantWrite
• Dec 28, 2023

Thanks everyone!!

 

[IndigoBlueWagon]

There are two lines, PNs 3B0 201 220E, 3B) 201 227C that run from from the tank to the fuel cooler, and a pair of lines 3B) 201 544CT that run from the cooler to the firewall. All are no longer available. Just so you know, total cost when available was about $600.

 

[CantWrite]

@IndigoBlueWagon

Thank you, I was actually looking for the metal line that is attached to the fuel cooler (i think its the supply), which I assume isn't available either. The rubber formed lines appear to be in decent shape.

I will continue to scour ebay, or copart etc.

In your opinion, is bypassing the cooler a bad idea and using rubber, nylon, or some metal line?

alright, I searched your part numbers and see you listed the ones I was after, thanks again!! What would be your recommended solution?

 

[IndigoBlueWagon]

I'd see if you can get someone to make them. People do it with brake lines all the time, might not be too difficult for fuel.

 

[PickleRick]

The fuel pressure is very low on these compared to the the gasser Passats.

I don't know of anyone with a BHW installed into another vehicle that used a fuel cooler. It's been in the mid to upper 90s all week here and my BHW has had no issues with the absence of a fuel cooler. Installed in a much heavier vehicle. Bypassing wouldn't be the end of the world.

If it were me I'd find the damaged section, cut it and barb either side of the hard line, then connect with appropriately fitting soft fuel hose. Double clamp on either side for redundancy.

On my 4 runner the hard fuel lines running to/from the tank to the engine bay were old emissions charcoal tank breather lines. They are 6mm OD, since they were there I figured I'd try them and if I had fuel starvation issues I'd upgrade later. Still there nearly 2 years later.

These engines are not super particular with their fuel delivery so long as it's clean and no air can enter.

 

[IndigoBlueWagon]

It's been in the mid to upper 90s all week here and my BHW has had no issues with the absence of a fuel cooler.

As far as you know. If the fuel gets too hot the ECU will cut boost and timing. You wouldn't notice it unless you're driving flat out. I agree that under most circumstances it's probably not an issue, but it does effect power and efficiency, just like too high air intake temps do.

 

[PickleRick]

I've never noticed a loss in boost, I have an egt and boost gauge. I don't drive it hard, those days are long behind me and I don't want to replace things I broke because I'm hard on my vehicles.

I've kept tabs on maybe 90% of the tanks I've ran through this since putting it on the road fall of 2021. Worst tank was 22.5 mpg and best was 25.5. Most seem to be between 24.5 and 25. Winter, summer, fuel station I stop at, highway or city driving do not seem to make much of a difference.

I never kept tabs on iat when I was driving the Passat but I do believe my intercooler mounted on my skid plate is sub optimal.

 

[zzdiesel]

I did replace one with rubber fuel line. No problem.

 

[CantWrite]

Thanks for the input. I like your idea @PickleRick to splice past the compromised section keeping most the rest intact. I have to work nightshfit from the office tonight, so I am going to go put it back together. But then I have a week off and this is first on the list followed by DS Window Regulator that busted during the winter.