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Draining or changing the diesel fuel filter and priming the fuel lines - for mk4 VW: Golf, New beetle, and Jetta TDI
difficulty: 1/5 back to 1000q: 1998-2003 TDI "how to" list back to 1000q: pumpe duse how to list
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Introduction
This article shows how to drain the fuel filter on your VW Jetta TDI, VW Golf TDI, or Beetle TDI, 1998-2006
other generation TDI fuel filter "how to": 1996-1999 mk3 fuel filter change, 2005.5-2006 Jetta/Golf fuel filter service 2009-2010 Audi A3 Jetta TDI fuel filter service 2004-2005 VW Passat TDI fuel filter change. Your owner's handbook and service manual calls for draining the fuel filter of water every 10,000 miles and changing it every 20,000 miles.Thismeansinstallanewfilterevery 20,000 miles and drain it halfway through it's life. This article gives tips on changing or draining the fuel filter and then priming the fuel system. If you are using high percentages of biodiesel such as 85% or 100% biodiesel, you should expect to change it early since biodiesel will clean out the old buildup and clog the fuel filter if there was significant build up in the fuel system. As a safe rough estimate, 1000 miles and then again at 5000 miles, your mileage may vary with biodiesel. A more economical idea is to install a small clear inline fuel filter before the main fuel filter to filter out larger particles and let you see how clogged the fuel filter may be. Early symptoms of a clogged fuel filter are stumbling at high rpms or lack of power. A general lack of power could also be limp mode, see 1000q: TDI limp mode for possible causes and the solution. Make sure that these symptoms are not caused by an air leak in the fuel line or a clogged pickup at the fuel tank. Bacterial or algal growth in the fuel tank can clog the pickup. If your car is a 2004-2006 pumpe duse TDI, it's also possible that the low pressure in tank electric fuel pump, the lift pump, is failing, bad, or clogged. This can cause hard starting or a stalled engine due to fuel starvation.
http://www.myturbodiesel.com/1000q/a4/fuel-filter-change-TDI-engine.htm
2012/12/10
How to change, drain, or replace a VW Jetta TDI fuel filter, also works for VW Golf a... Page 2 of 5
Fuel filter location circled in yellow. If you have a mk4 VW Passat TDI the fuel filter is to the right (looking at the engine) of the engine.
http://www.myturbodiesel.com/1000q/a4/fuel-filter-change-TDI-engine.htm
2012/12/10
How to change, drain, or replace a VW Jetta TDI fuel filter, also works for VW Golf a... Page 3 of 5
If you have a 2004-2006, make sure the car is off since there is an electric in tank fuel pump that pressurizes the fuel lines. To replace, loosen the phillps screw that holds it and remove the fuel lines. Pull off the wire mickey mouse pin in the direction of the arrow.Thenreleaseandslidethespringclamps back. The fuel lines may be stuck to the filter so try twisting the line to break the seal before pulling it off. You can leave the return lines on the T attached because you can just pull the T off.
Pull out the filter and replace the o-rings on the thermostatic T. Make sure to replace them or else excess air bubbles can cause fuel supply problems.Newonesshould come with the new filter. Wipe up any fuel spills and make sure that while you are doing this procedure, that there are no possible sources of ignition or open flames anywhere near the car and adequate ventilation to clear any fuel vapors. Make sure to wad a paper towel over the fuel line when you remove it. The fuel lines should not be under pressure if you have a <2004 but some fuel may spill out. If you have a 2004 or newer or any model with a lift pump in the fuel tank, the fuel lines will have some leftover pressure if you just had the engine running.
When you replace the fuel filter, fill it up with fuel to prevent a dry start (see more on priming below). Here's a video summarizing the procedure on a similar engine:
http://www.myturbodiesel.com/1000q/a4/fuel-filter-change-TDI-engine.htm
2012/12/10
How to change, drain, or replace a VW Jetta TDI fuel filter, also works for VW Golf a... Page 4 of 5
Here is what's inside the fuel filter housing, click to enlarge the thumbnails.
Priming the fuel system or purging air (if your TDI engine can't start if you changed the filter)
To prime the pump, first fill the fuel filter and fuel lines with fuel. If you didn't change the injectors or do something that emptied the fuel lines, just filling the filter should be enough. If you did empty the fuel lines and rail, prime the system fully. The method depends if you have an earlier or later style fuel system. Early styles (up to 2003 in North America) use a Bosch VE type TDI injection pump and no electric fuel pump. Later styles (2004+ in North America) are pumpe duse and use an electric fuel pump in the fuel tank.
http://www.myturbodiesel.com/1000q/a4/fuel-filter-change-TDI-engine.htm
2012/12/10
How to change, drain, or replace a VW Jetta TDI fuel filter, also works for VW Golf a... Page 5 of 5
Some people loosen the fuel hard lines at the injectors to purge air. This also works fine but if you just removed the fuel injectors, counterhold the injector bodies to avoid twisting their hold-downs.If you didn't, they'll be frozen in place and won't need to be counterheld. Wrap a rag and around the line to prevent fuel being sprayed everywhere. Do not use your hand to hold the fuel since the diesel is under pressure.Althoughyouonlysee"instantdeath"fuelpressureat the injector nozzle (in the cylinder and not exposed by loosening the fuel line), I would still avoid exposing bare hands to any pressurized fuel.
Comments or questions?
http://www.myturbodiesel.com/1000q/a4/fuel-filter-change-TDI-engine.htm
2012/12/10