TheSamba.com :: View topic - Replacing Firewall Fuel fitting, connnection to plastic line

Tue Sep 07, 2010 3:49 pm

sorry if this has been asked before, but i'm in the process of replacing the plastic firewall fuel fitting with a metal one and I'm also replacing that 4-5" of fuel line behind the firewall which connects to the plastic fuel line leading forward to the filter/pump. I found that small fuel line to be cracked on the ends and longitudinally, so I'm glad to replace it before it caused real damage. :shock:

It looked worse than any of the other fuel lines I replaced last year in the engine compartment, so please don't neglect this as I did.

my question:
the rubber line was very tightly (too tightly?) clamped onto the plastic line such that the plastic line was crimped/flattened. I'm wondering if this is normal or affected fuel delivery? I was also surprised that there was no "nub" at the end of the plastic line to make a stronger connection and wondering whether it may have been cut off previously.

Should I cut the crimped portion of the plastic line and lengthen the rubber fuel line to compensate? Should I worry about there not being a nub at the end of the plastic line and how tightly should I clamp down to make sure the connection is solid but not too tightly that the plastic line gets crimped again.

just an ordinary guy trying to keep his van from exploding.

thanks in advance.

Tue Sep 07, 2010 5:03 pm

You might consider simply running one continuous piece of good quality, high pressure fuel hose from you fuel pump straight through to the "T" connection that feeds the two fuel rails.

A second piece of larger diameter, short length hose might be slipped over the smaller hose where it passes through the hole that once held your plastic (now-to be metal) firewall connector.

Tue Sep 07, 2010 6:57 pm

....well, if you search hard enough, you find the answer...

tencentlife responded in this thread:
http://www.thesamba.com/vw/forum/viewtopic.php?t=387677&highlight=plastic+firewall+fuel+fitting

based on his suggestion, looks like I'll cut that short piece of crimped plastic line and attach the flex rubber line, with about 2" of overlap. I'll tighten, but not over-tighten.

thanks Gaff for your input as well. might consider doing that down the line.

Wed Sep 08, 2010 9:21 am

you should clamp it tight enough such that you cant by hand pull it apart, get a high quality clamp also. only use SAE 30R9 hose as it is resitant to todays mandated oxygenated gas. theold standard for FI systems was 30R7 now days 30R7 is being marked with a warning NOT to use it on FI systems, the gasoline has changed so we need to change the type of hose we install.

Wed Sep 08, 2010 10:06 am

When I replaced my fuel lines I dumped the plastic pipe and ran the hose direct from the pump thru a rubber grommet in the firewall to the tee on the engine, eliminating those 4 possible leaky joints. No problems for the last 3 years.

Wed Sep 08, 2010 6:29 pm

My fix was posted here: http://www.thesamba.com/vw/forum/viewtopic.php?t=397060&highlight=