VW Passat & Audi A4 1990-2000

Fuel Filter/Water Separator

Print

REMOVAL & INSTALLATION


Click image to see an enlarged view

Fig. Exploded view of the fuel filter

For component location identification and assistance with removal of this component, refer to the appropriate exploded view illustrations.

  1. Identifying the water drain screw
  2.  
  3. Loosen and allow approximately 1 liter of water to drain.
  4.  
  5. To drain the fuel, loosen the bleeder screw (item 14)
  6.  
  7. Identifying the seal
  8.  
  9. Replace the seal if damaged
  10.  
  11. Identifying the fuel filter
  12.  
  13. Observe the service change intervals.
  14.  
  15. Loosen with a strap wrench
  16.  
  17. Fill the filter with clean diesel fuel before installing.
  18.  
  19. Tighten the filter by hand
  20.  
  21. Identifying the seal
  22.  
  23. Replace the seal if damaged
  24.  
  25. Identifying the supply line to the injection pump (ensure it is securely seated)
  26.  
  27. Showing the O-ring (replace whenever removed)
  28.  
  29. Identifying the return line from the diesel injection pump (ensure it is securely seated)
  30.  
  31. Identifying the control valve (installation position arrow points to the fuel tank)
  32.  
  33. Below 60°F (15°C): Passageway to filter is open
  34.  
  35. Over 88°F (31°C): Passageway to filter is closed
  36.  
  37. Identifying the securing plate
  38.  
  39. Plate should be torqued to 3.7 ft. lbs. (5 Nm)
  40.  
  41. Identifying the return line to the fuel tank (ensure it is completely seated)
  42.  
  43. Identifying the check valve (installation position arrow points toward the fuel tank)
  44.  
  45. Identifying the bleed screw:
  46.  
  47. Torque to 7 ft. lbs. (10 Nm)
  48.  
  49. Loosen to drain
  50.  
  51. When changing filter, loosen to bleed
  52.  
  53. Identifying the seal (replace if damaged)
  54.  
  55. Identifying the fuel filter flange:
  56.  
  57. Fuel direction is marked by an arrow
  58.  
  59. Do NOT interchange connections
  60.  

 
label.common.footer.alt.autozoneLogo