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Discussion Starter · #1 ·
2013 Passat wagon was smoking and smelled strong of fuel. I opened it up and found fuel spraying all over the engine bay (mostly on the cat) from the middle aluminum fuel line just to the right of where it is mounted to the firewall.


https://www.dropbox.com/s/zjszxr60omib9s7/IMG_3289.jpg?dl=0

It was worn through by a valve that was mounted too close. Does anyone know what this valve is--a combi valve maybe?


https://www.dropbox.com/s/t3xh73uvt4sdfwe/IMG_3290.jpg?dl=0

It's above the EGR, here's where it mounts:


https://www.dropbox.com/s/ont65sqe5ynxchu/IMG_3279.jpg?dl=0

It looks like it routes from the crankcase to a tube that connects down here, right into the turbo intake:


https://www.dropbox.com/s/bd3pttwybyrl8oj/IMG_3292.jpg?dl=0

Replacing the entire rail looks like it may be a pita--other threads said that I'd have to buy the entire 3 line kit, maybe I can just slice the rail to the left of the damage and replace the hose connecting in with a longer hose. What type of hose do I need to replace (the one attaching to the aluminum line from the driver's side)?
 

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well because of the location and the problem with replacing that line we will cut and slip fuel hose well onto it, say at least 1.5 to 2 inches and double clamp it. i know of two that i have repaired this way and they have held for several years. just use good fuel injection rated hose and high pressure clamps
 

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2013?!?!? I didn't bother reading the rest, it's a "newish" vehicle. Take it in to the dealer and complain it's a safety issue. They will fix it as soon as you throw around the word of a lawsuit.
Take it to the dealer/


Also, this is the wrong forum if it is a 1.8T 2013:thumbup:
 

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Discussion Starter · #4 ·
Haha, no it's a 2003. So I bought some FI rated fuel hose and some FI clamps at Pepboys. But I didn't do the install yet because I realized that I can make a stronger fix due to where the hole is on the fuel line. Instead of being inside the firewall bracket like most people with this issue, mine is to the right halfway between the bracket and where the fuel line meets the fuel tube heading to the fuel rail. So, I have at least 2" on either side of the damaged part. I realized that there is another flare to the fuel line just to the right of the bracket (like where the tube connects), so what I want to do is get a replacement for the tube that screws onto the fuel rail, but with another few inches in length to the tube so I can have only one point that has to be clamped, and it will also have the advantage of meeting up with the flared part of the line. Can someone help guide me to where I can source a replacement tube that connects to the rail but with a few extra inches in length?

What is the screw type of connection called that's crimped onto the tube which connects to the rail?

Also what's the name for the type of clamps that are installed on the other end of that cable where it connects to the flared fuel line? What's the trick for removing these types of clamps?

Since my fuel line is still intact inside of the firewall bracket, does anyone have suggestions for how to reinforce the line at that point to prevent it from failing like it has on so many others?

Thanks!
 
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