Volkswagen Golf/Jetta/Cabriole 1990-1999

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.

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.

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.  

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

 
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