Replacing the fuel filter of diesel models

Attention: Do not allow diesel fuel to get on parts of the engine compartment.

Filter with pumping channel

1. Remove the drain plug (1 per resist. illustrations) and connect a diesel fuel extraction device to it (e.g. VAS5226). Draw out about 100 ml of diesel fuel and tighten the plug with a new gasket.



2. Loosen the bolts (see resist. illustration) diagonally by 1.5-2 turns, and then completely unscrew them and remove the filter cover.



3. If the filter cover cannot be removed, insert into the groove (And on the opposite illustrations) screwdriver VAS6543 and turn it.

Note: Groove size may vary.

4. Remove the filter element (1 per resist. illustrations) from the filter housing (4). Replace gasket (3) and install a new filter element.



5. Lightly moisten a new filter cap O-ring with diesel fuel and slide the O-ring onto the cap. Position the cap on the filter housing and push it evenly until it is fully seated.

6. Screw the bolts of the cover by hand, and then tighten them in the sequence shown in illustration 23.2 with a force of 5 Nm. Connect the hoses to the old fittings.

Filter with and without drain hole

7. Loosen the drain plug (1-1 on resist. illustrations, top) or turn it off completely (11-1). Put a transparent hose with a receiving container on the plug or fitting and start the engine. Allow about 0.3-0.4 liters of sludge to drain until clean fuel flows and turn off the engine. Disconnect the hose and tighten the plug to 7 Nm.




8. Loosen the bolts in sequence (1-5 per resist. illustrations) 1.5-2 turns, and then completely unscrew them and remove the filter cover together with the filter element. If the cover cannot be removed, insert into the groove (And in illustration 23.3) screwdriver VAS6543 and turn it.



9. On models without a drain plug, separate the filter element (3 on resist. illustrations) from the lid (1) and pull it out of the filter housing. Remove dirt and water from the filter housing.



10. On models with a drain plug, separate the filter element with a drain port (1 per resist. illustrations) from the lid (2) in the direction of the arrow (A) and pull it out of the filter housing. Remove dirt and water from the filter housing.




11. Remove from cover (1 per resist. illustrations) sealing ring (2), prying it with a screwdriver in a special groove (arrow). Lightly moisten a new O-ring with diesel fuel and insert it into the groove in the cap.



12. On models without a drain plug, lightly moisten the inner filter gasket with diesel fuel and insert the filter element into the filter housing.

13. On models with a drain plug, partially insert the filter element into the filter housing and hold it with your hand. Lightly dampen the inner filter gasket and drain port gasket (1 in illustration 23.10) diesel fuel. Rotate the filter element so that the drain port is facing the grommet in the cap (2), and install the filter element by pushing into the cover in the direction of the arrow (IN).

14. Install the cover with gasket on the filter housing and press it evenly until it is fully seated. Only after that, screw in the cover fastening bolts by hand, and then tighten them in a diagonal sequence (1-5 in illustration 23.8) with a force of 5 Nm.

15. On models with TDI-CR engines, finally fill and bleed the high pressure circuit of the fuel supply system (see chapter 4).