Author Topic: HOW TO: Replace the Fuel Filter on a TDI  (Read 8790 times)

Offline Rhyso

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HOW TO: Replace the Fuel Filter on a TDI
« on: 28 October 2010, 08:23 »
Following this thread
http://www.golfgtiforum.co.uk/index.php?topic=170706.0

Here is the workshop procedure if that helps  :smiley:


Remove engine cover panel

Removing:
Caution
Do NOT pull fuel hoses off fuel filter cover and do NOT lever at connection. Otherwise, leaks will occur and the upper part of the fuel filter can be damaged.
Ensure that no diesel fuel contacts other components in the engine compartment. Clean immediately, if necessary.

 
Carry out the following procedure:
–   Unscrew all bolts -arrows- from upper part of fuel filter and remove upper part of fuel filter.
 


If the upper part of fuel filter is stuck, loosen as follows:
The upper part of the fuel filter can be raised at assembly groove -arrow A- using angled screwdriver -VAS 6543-.
The assembly groove can be of different size, depending on the type of upper part.
Insert appropriate side of angled screwdriver -VAS 6543- in assembly groove -arrow A- and turn angled screwdriver -VAS 6543-.
Then the upper part of the fuel filter is raised.



Take filter -3- out of lower part of fuel filter.
 


Remove old seal -2- from upper part of fuel filter -1- by levering seal out of respective groove -arrow-.

Caution
Remove all diesel, dirt and water residues from lower part of fuel filter





Installing:
–   Insert new filter into lower part of fuel filter.

–   Moisten new seal -1- lightly with diesel fuel and insert into upper part of fuel filter -arrows-.
–   Place upper part of fuel filter with seal properly onto lower part of fuel filter, press on firmly and evenly until the upper part of fuel filter is correctly seated.
  Caution
Do NOT tighten bolts for upper part, before it is correctly seated onto lower part.
 


–   Screw all bolts into lower part of fuel filter and tighten hand-tight.
–   Then tighten bolts to 5 Nm according to sequence shown in illustration -arrows-.

Caution
This procedure prevents the seal from being damaged.

 



Thanks goes to mike. for posting the procedure  :nerd: