This write up is intended to help those who may have damaged or broken their fuel lines or fuel line connectors. Understandably, this is not a common problem, but it can occur by failing to properly remove the fuel line connectors from the fuel filter. This causes the plastic connectors to snap or fuel lines to bend and restrict the flow. The only alternative fix is replacing the entire fuel line(s), which can become very expensive, as the gas tank may need to be dropped.
This is NOT a write up on how to replace the fuel filter. That can be found here – http://forums.vwvortex.com/zerothread?id=1276409
Level of Difficulty – 2/10
Estimated Time to Completion – 1 Hour
Disclaimer - Use this guide at your own risk, I am NOT responsible for any damage that may incur to you or your vehicle! Read this guide in its entirety before attempting these steps. This process was performed on a 2001 Volkswagen GTI 1.8T, I cannot guarantee this will work on your vehicle.
- 1 Fuel Filter (1J0201511A)
- 1 or 2 Fuel Line Repair Kits (5/16th of an inch)
- 1 Hose Clamp
- Car Jack / Jack Stands / Ramps
- Phillips Screwdriver
- 7mm Socket/Wrench
- Utility Knife
- Dull Wire Cutters or Clamping Device
- Pot & Stove
Before You Begin:
Here is a shot of a broken fuel line connector.
This fuel line repair kit included nylon replacement lines. I found the kit at a local Part Source; it may be available at your local Auto Zone for you guys south of the boarder. Both of the factory line-to-filter connectors are 90-degree elbows but there was only one elbow and one straight connector available at this store. Ensure they snap onto your replacement fuel filter before purchasing.
Here is an illustration of the fuel lines, from the gas tank to the engine. This task is being performed on both fuel lines.
1) If you aren’t already on ramps or stands, begin by jacking up the vehicle near the passenger rear tire.
2) Once the car has been secured, locate and remove the fuel filter if you have not yet done so. Please follow the steps here http://forums.vwvortex.com/zerothread?id=1276409 in order to safely perform this task.
3) Remove the passenger side rear seat, pull back the felt and locate the opening to the fuel pump.
4) Unscrew the three Phillips screws and remove the panel.
5) Disconnect the fuel line (black) from the fuel pump and tie a string around the fuel line connector.
6) Push the fuel line connector under the panel to give yourself some slack underneath the car. Be careful not to pull too hard so that it gets stuck!
7) Hold your old and new fuel lines together and cut them with a utility knife at the same point to ensure the final length remains the same.
As ridiculous as these next couple steps may seem, they are imperative to ensure the line fixtures do not leak.
8) Boil a pot of water and submerse the end of the fuel line for a few minutes until the nylon becomes soft.
9) Then insert the connector and use your dull wire cutters to clamp the ring while the line is still soft.
10) As recommended by the maker of these replacement fuel lines, this task of softening the tip must also be performed on the vehicles factory fuel lines. Provided you have enough slack to do this, bring the pot outside, place it under the car and submerse the tip.
11) Insert the other end of the connector into the factory fuel line and clamp the ring.
12) Once the tank-to-filter line has been repaired, if required, repeat steps 7 – 13 to repair the filter-to-engine line.
13) Depending on the amount of filter-to-engine line to be replaced, submerse an appropriate length in boiling water to ensure it will bend along the same path as the factory line.
14) Once the fuel lines have been repaired, insert your fuel filter and snap the connectors into place.
15) Use your string and pull the fuel line back up and snap the connector onto the fuel pump.
16) Then put the seat back in its place.
17) There’s a good change your old hose clamp was rusted, so grab a new one. Ensure the fuel filter is in the correct position, slide the clamp around the filter and clamp it shut.
18) Finish by getting a friend to inspect for leaks at the connections while first turning over the engine. Remember, it will take some time for the engine to start up, as some of the fuel will have dripped out of the lines.
19) Grab a 6-pack and relax.
Thanks to my girlfriend Michelle for the pics
Modified by hipsiguy at 6:15 AM 6-10-2008