[Hirnbeiss]

The thin hard plastic line is sold at Advance Auto as something like “Emission Tubing”. It’s over there in that aisle you know I’m talking about, with the other tubing and small bags of things . Sorry, going from memory.

And don’t feel bad about breaking it - the stuff becomes as brittle as an icicle at this age.

 

[Tortelious]

If you substitute brake line for that plastic, you'll never break another one.

 

[Hirnbeiss]

If you substitute brake line for that plastic, you'll never break another one.

Insert Giphy here of Spock saying “Indeed”

 

[geronimomo]

I'm not seeing that vacuum reservior behind the left headlight. I'm going remove the wheel well cover and if I don't see the reservoir, I'm going to have to remove the bumper and headlight to get to the fender. I really hope it doesn't get to that point but I'm going to need to get this resolved pretty soon.

Also, not looking forward to replacing that line to the actuator on the passenger side of the car... In reading it here, that's a PITA.

The 2005's are a bit it different. When I went to take my ABS module out, I had to drill a hole through a metal plate that was in the wheel well to get to the bottom right screw of the ABS module. In the older B5.5 cars, based on posts I saw here, you didn't have to..

 

[geronimomo]

You don't need to remove either.

DIY: Replacing all Vacuum Lines on 2003 B5.5 V6 (ATQ)

Below you’ll find my instructions for doing your vacuum lines. It’s a straight forward procedure and should only take a few hours. Thanks for all those at PW for their advice: ScottPassat2.8, keithermadness, JaytheSnork, PZ, ashman78, mrmom, and Steve in Chicago! You guys are a wealth of...

www.passatworld.com

I'm not seeing the reservoir behind the headlight. In my checks, it seems the reservoir is in the fender or wheel well. I need to check the car really soon. If not, It's going to the Indie shop..

 

[Tortelious]

I'm not seeing the reservoir behind the headlight. In my checks, it seems the reservoir is in the fender or wheel well. I need to check the car really soon. If not, It's going to the Indie shop..

I'll snap some photos to show you where that length of tubing goes. Give me a few hours.

<edit> Step #9 in that DIY is what I am referring to.

 

[Tortelious]

If you see that white plastic connector at the end of my red tubing, that should be on yours and still intact, since it was all originally rubber tubing.

That black rubber tubing in the middle ^^^^ might have slipped down in yours if the plastic tubing it was attached to had broken into pieces. This is below the power steering reservoir.

And this is where that rubber tubing goes behind the windshield washer fluid reservoir and heads to the rear.

If you find any loose hanging rubber tubing anywhere in these areas, odds are that's what you're looking for. No need to trace it any further back towards what it attaches to. Just add a fitting where it's convenient and add your new stuff.

 

[geronimomo]

@Tortelious Thanks for the pics. I took another peek at my car tonight. Found that the plastic line to the drivers side combi valve is broken as well, shown below. Can I cut a bit of the rubber tubing where the blue arrows are pointing to, stick a plastic connector there and connect a new silicon tube which goes to the solenoid?

The left end of the plastic line in circled red above connects to the right end of the line circled in red below

From what I can tell, the left end of the line circled in red above is circled in red below and is on some kind of t-connector, which connects to the line circled in yellow below (which goes to the passenger side combi valve and connects to the solenoid in the picture?

 

[Tortelious]

@Tortelious Thanks for the pics. I took another peek at my car tonight. Found that the plastic line to the drivers side combi valve is broken as well, shown below. Can I cut a bit of the rubber tubing where the blue arrows are pointing to, stick a plastic connector there and connect a new silicon tube which goes to the solenoid?

View attachment 108252

You could either cut it down past the broken plastic end, or fish that broken end out of the rubber tubing. As long as it doesn't leak you're good to go.

To prevent that tube from getting broken again after you fix it, try feeding it under that solenoid plate. You can't break what you can't touch.

 

[geronimomo]

Question, any chance the vacuum hoses be exposed to oil or gas?

 

[geronimomo]

Realized I didn't order the check valve. I think the part number is 433-862-117, for the 2005 V6. Can anyone confirm please?

 

[John_E]

Try running the VCDS routine to set SAIP readiness monitor. Mine reported -100% of expected air flow boost. I then verified that my combi valve was getting no vacuum at its control port, but the F-hose was, which in turn pinpointed my problem to the solenoid-controlled vacuum activation switch for the combi valve. On the 1.8T, the solenoid switch is buried under the intake manifold.