Fuel Line Repair: Installation & Troubleshooting

Hello,
As vehicles age, the rubber ends of the clear fuel lines become increasingly hardened, causing them to loosen from both the ESP (Electronic Stability Program) system and the filter, as well as from the fuel lines themselves, making it impossible to securely reattach them and resulting in leaks.
VAG only offers a complete replacement of the entire piping system.
"I was able to find a suitable supply line for my Audi 80 B4/1Z (part number 028 130 309 C), but the available return line is much too long and can only be installed with excessive tension (part number 028 130 310 A). When I contacted the parts department for clarification, they referred me to the KD center, who responded by saying 'Install the part as it is available.' The result is shown in picture 1."
It is not possible to shorten the plastic pipe that has shrunk onto the brass fittings.
According to the spare parts catalog, replacing individual sections of the hose is not officially supported. However, a piece with dimensions 5.5mm x 3mm fits (part number N 101 207 03, which the parts department helpfully identified) and can be easily attached to the old plastic tubing with brass fittings using clamp or screw connectors.
Different sizes are needed for the inlet pipe; 7.3mm x 3mm or 9.3mm x 3mm should be suitable here.
The result with the repaired return line is shown in Image 2. Screw terminals are recommended for connecting to the ESP (Electronic Stability Program) and DiFi (Differential). The additional coupling on the left, next to the connection to the ESP, serves as a base for the hose clamp.
Best regards,

hi...

I highly recommend visiting "Hydraulikvertrieb"; they offer a wide range of services and can handle almost anything.

And it's sooooo cheap .


They have all kinds of radiator hoses with us, and much more...
Connectors are pressed in, so you don't have any work to do .

Of course, this is an alternative if you have access to a hydraulic system and it charges the labor costs through a separate account.
You can find the parts for my DIY version at a parts store (possibly brand-independent), priced like regular fabric or material, and they are usually available in the late afternoon or on Saturday mornings.
hg
Herbert.