Attention! Avoid getting diesel fuel on rubber parts and especially on cooling system hoses. Remove any fuel that has come into contact with these parts immediately. Otherwise, the rubber of these parts will eventually become unusable.
1. Unscrew the plug 2 of the ventilation hole (see illustration).
9.1. Unscrew the plug 2 of the ventilation hole:
1 - fuel filter clamp
2 - vent plug
3 - fuel supply hose from the tank
4 - fuel hose to injection pump
5 - clamp
6 - pressure reducing valve with connected hoses
2. Connect a low pressure hand pump with a condensate collection container, e.g. VAG 1390, to the vent by inserting the suction hose of the pump into it (cm-. illustration).
9.2. Connect a low pressure hand pump with a condensate collection container, e.g. VAG 1390, to the vent by inserting the suction hose of the pump into it
Attention!. Liquid must not enter the pump when removing condensate.
3. Drain approximately 100 cm3 of condensate from the fuel filter (almost one full cup), by pumping the hand pump lever.
4. Disconnect the hand pump, screw plug 2 into the air vent of the filter (see illustration 9.1).
5. Start the engine. Bleeding of air from the fuel system will be performed automatically.
6. Inspect the fuel system for leaks, especially at the fuel filter attachment and fuel filter connections.
Fuel filter replacement
7. Cut the fuel hose clamps 3 and 4 with side cutters and disconnect the hoses from the filter (see illustration 9.1).
8. Remove clip 5 (see illustration 9.1).
9. Lift the pressure reducing valve 6 together with the connected hoses up and remove it from the filter (see illustration 9.1).
10. Unscrew the clamping bolt 1 of the filter clamp and remove the filter from the holder (see illustration 9.1).
11. Fill the new fuel filter with clean diesel fuel. This technique makes it easier to start the engine after changing the filter.
12. Install the filter in the clamp and tighten clamping bolt 1 of the clamp (see illustration 9.1).
13. Replace the pressure reducing valve O-ring 6 with a new one (see illustration 9.1), by soaking it in diesel fuel before installation.
14. Replace the pressure reducing valve and secure with clamp 5 (see illustration 9.1).
15. Put fuel hoses 3 and 4 on branch pipes and fix them with collars.
Attention! Do not interchange the inlet and outlet hoses. Be guided by arrows on hoses which designate the direction of the movement of fuel on a hose.
16. Start the engine. De-airing will be performed automatically.
17. Inspect the fuel system for leaks, especially at the fuel filter attachment points and fuel hose connections.
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