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Discussion Starter · #1 ·
My wife said after filling up her 2013 Passat wagon was smoking and smelled strong of fuel. I opened it up and found fuel spraying all over the engine bay from the middle aluminum fuel line just to the right of where it is mounted to the firewall.



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



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



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



Replacing the entire rail looks like it may be a pita, 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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I viewed your photos and none of the parts look familiar to me. I assume you have the 1.8T engine? Especially since you mentioned "turbo".

Seems very unusual for a metal fuel line to chafe through like you experienced. I wonder if that part that rubbed against it is an aftermarket part?
 

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that valve is part of your PCV system (pressure control valve).

i cant say for certain, since i do not have the 1.8t model..but that valve I believe your crank case ventilation valve. basically controls vacuum of air/fumes in your engine. if its in the way just go to the general auto store and grab some hose and extension..they will have PCV specific hose available and it can come packaged or you can buy off a real by the foot. Judging by the oil sludge in your system you may also consider picking up an after market catch can to help reduce the oil vapor in your vacuum lines.

Catch can is basically a can with an inlet and out let hose. your vacuum runs thru the can and the oil vapors drop and collect at the bottom of the can because of gravity. they cost anywhere from $30 - $100 but all do the same job.
 

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Discussion Starter · #6 ·
So it turns out that the valve which wore through the fuel line is indeed the crankcase vent valve. Usually it's located on the other side of the metal tube, near the turbo. The last owner upgraded the turbo to a K4, and the larger size of the turbo forced him to relocate the valve. I'll see about extending it out to relocate it so it won't repeat the same problem.

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?

I've been meaning to install a catch can on my rx-8, so I guess I'll do both at the same time.

Thanks!
 
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