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In order to run blends of biodiesel greater than 20% (B20) in your Volkswagen TDI engine, you will need to install a hose retrofit kit to prevent the hoses from rotting and leaking.  The following kit is for model years 1998 through 2003 for all VW TDI engines.  The hose is provided along with a fuel return terminator pre-cut and crimped for easy installation.

I have installed this kit on two 1999 VW Jetta TDIs and have put over 120k miles on the hoses without any issues.  Installation is simple and only requires a pair of sharp scissors to cut the hose to length and a pair of pliers to remove the existing hoses.

Mapawatt Instructions

1. Remove the plastic cover from the engine if it is still installed.  This will require the use of a socket wrench and metric socket. (10-12mm depending on year and if nuts are original)
2. You will see small return hoses that are jumpered between each of the four injectors to the engine.  These will be replaced with viton hoses cut to length.
3. You will also see a terminator hose on the last  injector on the left side of the engine.  This will also be replaced with the viton terminator hose.
4. There is a primary return hose that runs from the rightmost injector back to the injection pump.  This is the longest of the return hoses and will also be replaced.
5. The rest of the stock fuel supply hoses are alcohol-resistant and do not need to be replaced.
6. Remove each jumper hose and cut a section of viton hose the same length as the jumper.  Install the new viton jumper in place of the old.
7. Do this for all four jumper hoses being careful to cut the viton hose to the exact length so you will have enough for the primary return hose. (there is some extra length so this should not be an issue)
8. Replace the fuel return terminator hose with the viton terminator hose supplied.
9. Remove the primary fuel return hose from the injector and injection pump.  
10. Cut a new fuel return hose to the same length as the original.  Install it in place of the old hose.
11. Double-check all hose connections to make sure they are secure.
12. Inspect hoses to make sure they were not sliced or damaged during installation.
13. Replace the Engine cover and start the engine.

You are now ready to fill up with B100!