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    Thread: DIY - Fuel Line Repair

    1. 06-10-2008 08:44 AM #1
      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.


      Tools/Parts Required:

      - 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
      - String


      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.


      The Process:

      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.


      Good Luck!!!


      Thanks to my girlfriend Michelle for the pics



      Modified by hipsiguy at 6:15 AM 6-10-2008


    2. Banned Spark-'s Avatar
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      06-10-2008 08:57 AM #2
      How long does this take?

    3. 06-10-2008 08:58 AM #3
      Quote, originally posted by Spark- »
      How long does this take?

      That info is at the top


    4. Member liloldbie's Avatar
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      06-10-2008 09:00 AM #4
      Wow, awesome write up! This would save thousands from a dealer repair. Should be in the FAQ

    5. Banned Spark-'s Avatar
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      06-10-2008 09:01 AM #5
      Quote, originally posted by hipsiguy »

      That info is at the top




    6. 06-10-2008 10:14 AM #6
      I'll mirror this tonight on dubdiy.net

    7. 06-10-2008 03:37 PM #7
      Bump

    8. Senior Member 87vr6's Avatar
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      06-10-2008 03:42 PM #8
      Quote, originally posted by hipsiguy »
      Bump

      You don't need to bump it, hit the report post button and send a message to the MODs saying you think it should be added to the DIY section.


    9. 07-27-2008 09:40 AM #9
      THis is a good DIY! I broke one of my fuel line connectors in the engine bay right next to the coolant where line goes to the fuel rail.. I must do this..
      01' BT Jetta
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    10. Member nmjetha's Avatar
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      05-10-2009 11:16 PM #10
      Where the heck did ya find those fuel line connectors can't find them online?

      thanks


    11. Member nmjetha's Avatar
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      05-11-2009 04:45 PM #11
      Nevermind local bumper to bumper store had almost the same one, but I would use a compression fitting to connect them. It is more secure the guy showed me.

      thanks


    12. Member JAYMEN's Avatar
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      05-14-2009 08:26 AM #12
      Did this repair last night.

    13. Member dj givv's Avatar
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      07-30-2009 12:36 PM #13
      nice

    14. 07-30-2009 02:46 PM #14
      Very nice write-up!

    15. Member Evenodds20's Avatar
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      08-08-2009 03:53 PM #15
      i just broke the clip on my fuel line going from the filer to the engine. despite all my research i still got impatient and rushed. anyways i just went and got some double sided barbed union connectors and a few feet of fuel grade 5/16 hose and a few hose clamps. cut the broken connector off the factory fuel like, stick one side of the barbed union inside as far as you can get it. its really tight but i still put a small clamp on it just to be safe. then put the rubber fuel like on the other end of the barbed union, clamp it and stick the other end of the rubber fuel line on the fiter and clamp as well. good as new. ill reaplase it all with braided fuel like eventually but this will probably last a lifetime if i needed it to.
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      01-10-2010 11:39 PM #16
      ill be doing this tomorrow

    17. 08-15-2010 05:20 AM #17
      Very good DIY but would be useful if you actually gave exact PN and where to buy like other reply. internet search ... nothing, you stating local auto part store just doesn't get it. BTW what I searched was Titan fuel line repair 23-6035-8 and came up with nothing. Anybody have a source for the repair kit. I don't need it right now but I would be a lifesaver if connector broke while changing filter and having the fix on hand

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      03-04-2011 07:12 PM #18
      great diy , i know this is an old thread, but.... the part numbers i got were 800051 for the 90 degree. you can get them at autozone, thats were i got mine from, had to order the 800051 they don't have that one stocked. price for each was $19.99.
      Last edited by truefire97; 03-12-2011 at 12:57 PM.

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      03-12-2011 12:57 PM #19
      Quote Originally Posted by truefire97 View Post
      great diy , i know this is an old thread, but.... the part numbers i got were 800051 for the 90 degree and 800054 for the straight one. you can get them at autozone, thats were i got mine from, had to order the 800051 they don't have that one stocked. price for each was $19.99.
      the 800054 isn't the right part.

    20. 03-29-2011 01:26 AM #20
      I need to do this.

      A fellow Vortexer sent me an OEM connector cut to length.

      I just never have confidence on those barbs.

      After this write up, I think I am going to try this this weekend.

    21. Member BRES's Avatar
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      05-24-2012 04:15 PM #21
      does anyone have a more recent part number for the fuel repair kit?

      i went to O'Riley here and they didn't know wtf I was talking about...

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      05-26-2012 03:37 PM #22
      Alright so this is the part number is got from NAPA. I'll be doing this repair today.



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      05-26-2012 03:49 PM #23
      Test fitted into new filter and it clips on great!



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      01-02-2013 03:24 PM #24
      i tried doing my filter today one of my clips was very very brittle and broke the clip going to engine. Hopefully i can do this this week. I never fully took my old filter off so its still on there with broken clip and i dont think its leaking at all.
      Dusty

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      01-02-2013 08:42 PM #25
      Sent you a pm


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      07-24-2013 03:24 PM #26
      I know this is kind of an old thread but I was just wondering, does anyone know if it is possible to replace the whole fuel line (from the filter to the pump) by attaching a piece of string or small rope to one end and pull it through and then use the string/rope to pull then new line back through?

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      10-08-2013 01:01 PM #27
      added to 1.8t FAQ
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      10-08-2013 01:35 PM #28
      Quote Originally Posted by groggory View Post
      added to 1.8t FAQ
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    29. 12-10-2013 04:25 AM #29
      Quote Originally Posted by H_C View Post
      I know this is kind of an old thread but I was just wondering, does anyone know if it is possible to replace the whole fuel line (from the filter to the pump) by attaching a piece of string or small rope to one end and pull it through and then use the string/rope to pull then new line back through?
      Hi, yet again, apologies for dragging up an old post but as H_C asked...does anybody know ' if it is possible to replace the whole fuel line (from the filter to the pump) by attaching a piece of string or small rope to one end and pull it through and then use the string/rope to pull then new line back through?' (i.e. once the fuel line has been unclipped from the top of the tank/pump can it just be pulled all the way through from either above or below (once the other end has also been unclipped from the filter) and then 'simply' replaced with an equivalent OEM line by feeding it through the same path using the string? The only reason I ask is becasue I broke the connector going to the fuel filter and rather than cutting and splicing two lines together I was thinking about changing the entire line - seeing as though the line has to be unclipped and slackened off anyway).

      H_C did you ever figure this out? Or does anybody else have any other first-hand experience with this?

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