Classic VW BuGs How to Replace Install New Steel Fuel Line for Beetle Ghia

Here is a short video on replacing your clogged or rusty steel fuel line in your Vintage VW. You can bypass the tunnel and install it next to the brake line.

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Chris Vallone

[Biglug]

Thanks for this video. I have been trying to figure out how to do this for a while now. Looks much easier than trying to fish a new line though the tunnel!

[Aircooledbugger]

Bending the line to fit around the pedals was a bit of a nightmare, but without you I would have tried to fit it back through the tunnel and probably given up. Thanks!

[digitalbase]

Mr Valone your videos are awesome and an asset to the Vw community. Cheers from the land down under 🇦🇺

[gregorydickman]

Many thanks for this video, Chris. I ran my stainless steel line in this fashion, but didn't connect yet because she started beautifully. No gas leaks/fumes front or rear; but, the cabin reaks of gas-- so I am still thinking leak in tunnel. But your video helped me immensely running an alternate line just in case. Again, many, many thanks for sharing your knowledge.

[BobSugar-ie]

Now this makes the most sense by far from the other disasters of attempts made on other videos. Especially if your car is all together like mine

[rupe]

Since the OEM fuel line is inside the tunnel and raised above the floor it will not be more rusty than the exposed ends, which can easily be seen. I would strongly suggest blowing the line clear with compressed air, then flushing it with solvent, before going through the chore of a replacement line. Now, the main reason to secure a replacement along side the brake line is because the OEM fuel line is tack welded on brackets that also support the tube for the clutch and throttle cable. IOW, if you were to just snake a new line through the tunnel it will rattle like a bastard because it's not supported. You'd have to cut the tunnel open to gain access to that bracket. (driver's side right below the hand brake pivot point) The main reason to install a fuel filter up by the carb and not under the car is because that location is below the fuel level, meaning every time you change a filter the gas will run down your arm. Also consider the higher location is easier to inspect so you know when it's dirty. Either way, when you are done don't forget to seal up any holes with silicone to prevent rain water from sneaking under the floor mats.

[alt]

Video makes it very clear how to replace. Good job!

[jessegarcia]

Why are you using clamps on the OE fuel lines? I’ve never used clamps on any vw fuel line they only make 3-5 lbs of pressure and the braid around those lines is made to get tighter like a Chinese finger trap. I’ve never had any leaks vw fuel lines should be replaced every couple years anyway but just wondering why you decided to use them.

[domenicaazzolini]

Hi Chris, I think I may have pierced the gas line with a self tapping screw, while trying to install a center console/cup holder, over the tunnel of my 65 bug. First question is this possible? If so, what would you suggest doing? Look forward to hearing back! It’s my daily driver, I hope you find the time soon.😬
Thank you,
Domenica Azzolini

[Volkswagenplanet]

jobs are so much easier when you work on nice clean stuff. Last but not least and have all the right tools to do the job. good video

[davidkabara]

Needs grommets where the lines go through the sheetmetal. Cut the grommet and slip it over then fit in in the hole over the lines, use sealant too.

[stapletonfamily]

I know this is an older video, but I’m about to do this . How big (inner diameter) was the steel line you ran ? Thanks !

[yetirider]

Is that safe .... thinking of doing that .... with factory steel lines.... is rubber better then steel.... they make replacing the gas line so hard

[gregorydickman]

Hi Chris. What did you do about the grommets. Just drill them out.

[jamesdesrosiers]

On my 65 Bug I fed a wire (5 gal. bucket handle) into where the gas line came out in the back to under the back seat. Then I fed a new copper line into the tunnel though the trunk along the old gas line until the end got under the back seat also, and connected the copper over the wire and fed the copper & wire until a 2 feet or so of copper line came out the though to the back. I used the wire again to fish the copper tube up from the tunnel to the gas tank pulling the line from the back to front. I epoxy glued the new line to the old one where I could get access.
It was a pain.

[bigtasty]

Awesome video! Definitely going to tackle this project within the next few weeks. 👍

[NA]

We fixed the line in the tunnel, afraid it will have issues again. Just what I needed.

[reidw.]

Hey chris! Love the channel and all the tips. But I just bought another Baja to fix up and noticed that the fuel line was.. metal? Should I replace it with the plastic tubing?

[rtdm]

Man thank you you been a big help with these videos Chris

[guyduke]

For all those concerned about the line running inside the vehicle, why not just run a hard line from the front wall to the back wall mounted in the same way then rubber each end?!?!?