1979 VW B1 Passat Estate - Ready for MOT

For things that won't unscrew I usually find that Plusgas works most of the time. The odd time it doesn't I give it a second dose of Plusgas then a squirt of WD40 (or just cheap Wilkos equivalent) - the WD40 is a dispersive so it drives the Plusgas into whatever joint you've applied it to. The sender probably may have a seal which will have gone hard with age - but giving it a good soak with releasing agent usually helps. Just remember not to make any sparks when working near fuel tanks - if you need to use a hammer for example use a copper or plastic one to tap the sender round.

I'm in the Handbridge area - but Sunday alas I am working all day.

Ok, I quickly made this in paint to show where the fuel lines run on the Golf, obviously your engine is mounted differently in the Passat but it should give you an idea as to what to look for!   



 
Not 100% certain how the fuel system works on the Passat, but as you can see its relatively simple on the Golf which is hopefully similar. Fuel feed and return lines come from the tank to the left hand side at the bulkhead. From there the feed line runs to the fuel pump (mounted low down on the block) and the return goes to the pressure regulator. From the regulator the fuel feed runs to the carb and that's about it! 

Note that the golf doesn't have a pump in the tank, I discovered this yesterday when my car ran out of fuel and was a real pig to bleed the fuel lines through to the pump! Also note that in this picture I believe the fuel filter is mounted incorrectly, as far as I am aware the filter should ideally be after the pump rather than before it (as it is easier to push fuel through a filter compared to drawing fuel through the filter to the pump!)

I hope this is of some use to you, but like I say I am not 100% certain on how the fuel system is set up on the Passat!

Mike.

Cheers for the above guys! Mikkey, my layout is slightly different but I figured out my setup now Also thanks outrage, but as far as I can see there's no stickers or anything, not that it matters too much now

Fairly busy day for me! Weather was great so got in a full wash and wax so at least the bodywork has some protection. Found a few small rust spots on the paintwork, but really nothing to worry about. Maybe a few hours work in total to get them sorted.

Totally flushed out the coolant system today as It was empty and has clearly leaked previously - loads of build up for blue crystals around the pipework. Filled with warm water now and gonna check levels/leaks tomorrow, then flush again and replace with coolant. Does anybody know which sort I need? There's loads on the market!

Also managed to run a gravity feed to the fuel pump instead of the carb - all seems to working great, managed to get her idling quite happily and she sounded excellent and bassy while revving. Oil pressure seems solid too. Didn't want to run the engine too long as the coolant system hadn't been sorted at this point. I did forget that I'd disconnected the fuel return at the tank, so ended up with a nice puddle of petrol in the boot. Live and learn!

Should have all the measurements to buy all new fuel lines now so they will go on order tonight. Once these are fitted and coolant added, in theory there's no reason she won't move under her own steam (breaks, exhaust and gears dependant!)

Also, does anyone know what this is (torn silver pipework) and where I can get a new one? It runs from the engine block to the air filter area, so not sure of what it does!



Also another obligatory video of engine running.

Reeeeesult! Well done for sticking with it, and for learning as you go. Weird how everything was out of synch in the first place though, considering it was theoretically running when it was taken off the road?
Keep up the great work!

Just read this through from the beginning, nice car, I like early Passats!

Likewise with taurus, if you need a hand with something i'd be happy to come over. I'm even nearer than he is though, as I too live in Great Boughton, we must be pretty damn close to each other!

Thanks Georgesx, I might have to take you up on that when it comes to tuning as I've no idea at all!

Gonna check out ces tonight, been in need of a decent auto factor as been relying on imports from Germany so far! Wonder if they sell fuel lines? Wouldn't mind getting them fitted this week!

This is great news! Glad hooking the fuel line up to the pump got it going for you! As Andrewbaran has posted above, I tend to go to Eurocarparts for my general stuff (Servicing parts, brake pads etc) and VW Heritage is brilliant for some of the more specific parts (Headlights and a throttle pedal to gearbox cable in my case!)

Just check the provenance of any parts from ECP - some of the old trusted brands were bought up and their names used to box cheap foreign made components. I had to source some wheel bearings a while back in a hurry and CES only had one in stock. I was forced to get the other one from ECP. The CES one lasted - well it's still going strong. The ECP one failed within a fortnight.

Unless you really need to remove the tank I'd leave it. I've seen tanks laid up for years and whilst the fuel in them is rank there's often no debris in them providing they've not had water in them. It's worth fitting an inline filter in case there is any curse word coming out - easier to spot and replace a clogged inline filter than let it get into your pump. If there is old fuel in there just drain it out and use it in a lawn mower or something.

Ok I'm going slightly insane. Where the HELL do I buy fuel lines from? Everywhere online is being utterly useless and no stores sell what I need!

I specifically need 1/4" total diameter tubing ideally clear or yellow (tygon etc). This is what's currently on the car and it would be a bonus to be able to check the pump is still drawing fuel in months/years time just by looking under the car.

Any suggestions?

Ta!