Volkswagen Cars 2000-05

Fuel Filter/Water Separator

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Draining Water



Although Diesel fuel and water do not readily mix, fuel does tend to entrap moisture from the air each time it is moved from one container to another. Eventually every Diesel fuel system collects enough water to become a potential hazard. Fortunately, when it's allowed to settle out, the water will always drop to the bottom of the tank or filter housing. Some Diesel fuel filters are equipped with a water drain; a bolt or petcock at the bottom of the housing.

Although diesel fuel and water do not readily mix, fuel does tend to entrap moisture from the air each time it is moved from one container to another. Eventually every diesel fuel system collects enough water to become a potential hazard. Fortunately, when it's allowed to settle, the water will always drop to the bottom of the tank or filter housing. Some diesel fuel filters are equipped with a water drain; a bolt or petcock at the bottom of the housing.

Although diesel fuel and water do not readily mix, fuel does tend to entrap moisture from the air each time it is moved from one container to another. Eventually every diesel fuel system collects enough water to become a potential hazard. Fortunately, when it's allowed to settle, the water will always drop to the bottom of the tank or filter housing. Some diesel fuel filters are equipped with a water drain; a bolt or petcock at the bottom of the housing.

At The Filter
  1. If the filter is equipped with a water drain at the bottom, place a pan under the drain to catch the water and fuel.
  2.  
  3. If equipped, loosen the vent bolt on the filter base. If there is no vent, loosen the return line at the pump (the line not connected to the filter).
  4.  
  5. Loosen the bolt or valve. When fuel flows in a clean stream, close the drain and tighten the vent or return line.
  6.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. If the filter is equipped with a water drain at the bottom, place a pan under the drain to catch the water and fuel.
  4.  
  5. If equipped, loosen the vent bolt on the filter base. If there is no vent, loosen the return line at the pump (the line not connected to the filter).
  6.  
  7. Loosen the bolt or valve. When fuel flows in a clean stream, close the drain and tighten the vent or return line.
  8.  



Click image to see an enlarged view

Fig. On most diesel fuel filters, a water drain screw (bottom) is provided for bleeding any accumulated water from the fuel system

  1. If the filter is equipped with a water drain at the bottom, place a suitable filter under the filter to catch the water and fuel.
  2.  
  3. Remove the retaining clip that secures the control valve (located on top of the filter), then remove the valve, leaving the two lines connected.
  4.  
  5. Loosen the drain screw, and allow any accumulated water to flow from the filter. When clear diesel fuel flows from the screw, tighten the screw securely.
  6.  
  7. Using a new O-ring, install the control valve, and secure the retaining clip.
  8.  
  9. Start the engine and accelerate a few times to clear any air in the system. Check for bubbles, which indicate an air leak in the system.
  10.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. If the filter is equipped with a water drain at the bottom, place a pan under the drain to catch the water and fuel.
  4.  
  5. If equipped, loosen the vent bolt on the filter base. If there is no vent, loosen the return line at the pump (the line not connected to the filter).
  6.  
  7. Loosen the bolt or valve. When fuel flows in a clean stream, close the drain and tighten the vent or return line.
  8.  

At The Water Separator
  1. Raise and safely support the vehicle. Remove the fuel filler cap.
  2.  
  3. At the separator, connect a hose from the separator drain to a catch pan.
  4.  
  5. Open the drain valve (3 turns) and drain the separator until a steady stream of fuel flows from the separator, then close the valve.
  6.  


NOTE
Don't forget to install the filler cap.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the fuel filler cap.
  4.  
  5. At the separator, connect a hose from the separator drain to a catch pan.
  6.  
  7. Open the drain valve (3 turns) and drain the separator until a steady stream of fuel flows from the separator, then close the valve.
  8.  


NOTE
Don't forget to install the filler cap.



Click image to see an enlarged view

Fig. The water separator includes a sensor that flashes the glow plug light when draining is required

  1. Raise and safely support the vehicle. Remove the fuel filler cap.
  2.  
  3. At the separator, connect a hose from the separator drain to a catch pan.
  4.  
  5. Open the drain valve (3 turns) and drain the separator until a steady stream of fuel flows from the separator, then close the valve. Don't forget to install the filler cap.
  6.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the fuel filler cap.
  4.  
  5. At the separator, connect a hose from the separator drain to a catch pan.
  6.  
  7. Open the drain valve (3 turns) and drain the separator until a steady stream of fuel flows from the separator, then close the valve.
    NOTE
    Don't forget to install the filler cap.

  8.  

Removal & Installation




WARNING
Do not allow diesel fuel to contact the coolant hoses. If this happens, wipe it off and wash the hoses with soap and water immediately.

  1. Remove the retaining clip.
  2.  
  3. Remove the control valve from the filter with the fuel lines attached.
  4.  
  5. Disconnect the hoses from connections (1) and (2).
  6.  
  7. Remove the filter assembly.
  8.  

To install:

  1. Use a new O-ring and install the control valve on the filter.
  2.  
  3. Install the retaining clip.
  4.  
  5. Connect the hoses to connections (1) and (2) and secure them with clamps.
  6.  
  7. Start the engine and check for leaks.
  8.  



Click image to see an enlarged view

Fig. Fuel filter assembly-Diesel engines


WARNING
Do not allow diesel fuel to contact the coolant hoses. If this happens, wipe it off and wash the hoses with soap and water immediately.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect:

    Fuel pressure and return lines
     
    Retaining clip
     
    Regulator valve and O-rings
     
    Filter assembly
     

  4.  

To install:

  1. Install the filter.
  2.  
  3. Install the regulator valve and new O-rings
  4.  
  5. Install the retaining clip.
  6.  
  7. Connect the fuel pressure and return lines and secure them with clamps.
  8.  


    Click image to see an enlarged view

    Fig. Fuel filter assembly-1.9L (ALH) engine shown; other engines similar




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.  


    Below 60°F (15°C): Passageway to filter is open
     
    Over 88°F (31°C): Passageway to filter is closed
     

  33. Identifying the securing plate
  34.  
  35. Plate should be torqued to 3.7 ft. lbs. (5 Nm)
  36.  
  37. Identifying the return line to the fuel tank (ensure it is completely seated)
  38.  
  39. Identifying the check valve (installation position arrow points toward the fuel tank)
  40.  
  41. Identifying the bleed screw:
  42.  


    Torque to 7 ft. lbs. (10 Nm)
     
    Loosen to drain
     
    When changing filter, loosen to bleed
     

  43. Identifying the seal (replace if damaged)
  44.  
  45. Identifying the fuel filter flange:
  46.  


    Fuel direction is marked by an arrow
     
    Do NOT interchange connections
     



WARNING
Do not allow diesel fuel to contact the coolant hoses. If this happens, wipe it off and wash the hoses with soap and water immediately.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect:

    Fuel pressure and return lines
     
    Retaining clip
     
    Regulator valve and O-rings
     
    Filter assembly
     

  4.  

To install:

  1. Install the filter.
  2.  
  3. Install the regulator valve and new O-rings
  4.  
  5. Install the retaining clip.
  6.  
  7. Connect the fuel pressure and return lines and secure them with clamps.

    Click image to see an enlarged view

    Fig. Fuel filter assembly-1.9L (ALH) engine shown; other engines similar

  8.  

 
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