Engine 1.9-I-TDI / 110 hp
Removing water from the fuel filter
The fuel filter is located on the left side of the cylinder block behind the generator.
Remove the air pipe, for which loosen the clamps A (pic. 1.12) and unscrew bolt B.
Unscrew the bleed screw 3 (pic. 1.13).
Unscrew valve 5 from the bottom of the fuel filter (pic. 1.13) to remove water and drain about 100 cm3 of the liquid into a container underneath. For purposeful draining of the liquid, a hose can be put on the valve.
Tighten the valve to remove water by hand.
Tighten the bleed screw 3 (pic. 1.13).
Install and secure with clamps A (pic. 1.12) and a bolt into the air pipe.
The removal of air from the fuel occurs automatically when the engine is started. After repeatedly increasing the engine speed, the fuel should flow through a transparent hose without air bubbles.
Check for fuel leaks, especially at the hose connections to the fuel filter.
Fuel filter replacement
Remove the air pipe, for which loosen the clamps A (pic. 1.12) and unscrew bolt B.
Unscrew valve 5 from the bottom of the fuel filter (pic. 1.13) to remove water and drain all the liquid into a container underneath.
Unscrew the nut clamping the clamps of the holder 3 (pic. 1.13). and remove the fuel filter with the fuel hoses connected to it from the holder.
Unscrew the fuel filter from the top of the filter. To do this, the filter can be held with a 17 mm wrench installed at the base of the bleed screw.
Moisten a new O-ring and rubber gasket with a little diesel fuel.
Fill the new filter with clean diesel fuel. This is necessary for faster engine starting.
Screw the fuel filter securely into the top of the filter.
Install the filter in the holder and tighten the nut clamping the filter holder clamps.
Install and secure with clamps A (pic. 1.12) and a bolt into the air pipe.
Start the engine and visually check for fuel leaks.
Engine 1.9-I-TDI-115/130 HP
Fuel filter replacement
Remove the dipstick to measure the engine oil level.
Remove the top engine cover. To do this, remove three plugs from the casing and unscrew the three nuts located under the plugs.
Remove the lower mudguard of the engine compartment.
Unscrew the bolt and set aside the top of the filter with the fuel hoses connected to it (see fig. 1.14).
Unscrew screw 1 (pic. 1.14) filter holder and remove it.
Fill the new filter with clean diesel fuel. This is necessary for faster engine starting.
Install the filter in the holder, lower it down and fix it with screw 1 (pic. 1.14).
Install the top of the filter onto the filter and secure it with the bolt.
Install the lower engine compartment mudguard, upper engine cover, and engine oil dipstick.
Start the engine. The removal of air from the fuel occurs automatically when the engine is started.
Visually check for fuel leaks.
Engine 2.5-I-TDI
Removing water from the fuel filter
Remove the cover from the right side of the engine compartment.
Unscrew screw 2 to remove water from the fuel filter (see fig. 1.15).
Do not allow diesel fuel to enter the cooling system hoses. Hoses that have been exposed to diesel fuel for a long time must be replaced.
Connect the hose of the manual vacuum pump VAG 1390 with a container equipped with a water drain cock VAG 1390/1 to the hole for the water removal screw on the fuel filter (pic. 1.16).
Use a vacuum pump to suck out about 100 cm3 of fluid from the fuel filter.
Disconnect the hand vacuum pump hose from the water drain hole on the fuel filter.
Screw in screw 2 (pic. 1.15) into the fuel filter and tighten it to 4 Nm.
Start the engine. The removal of air from the fuel occurs automatically when the engine is started.
Visually check that there are no fuel leaks, especially at the hose connections to the fuel filter.
Fuel filter replacement
Loosen the clamps and remove the fuel hoses 2 and 3 from the fuel filter fittings.
By pulling, remove the spring clip 5 (pic. 1.15) control valve mountings.
Remove control valve 6 (pic. 1.15) along with connected pipelines.
Loosen the bracket nut and remove the valve fuel filter.
Fill the new fuel filter with clean diesel fuel for a quick start.
Install the fuel filter to the bracket and secure the bracket clamp with the nut.
Lubricate a new sealing ring with a thin layer of fuel, install it and the control valve 6 (pic. 1.15) in place and secure with spring clamp 5.
Install fuel hoses 2 and 3 (pic. 1.15) on the fuel filter and secure with clamps. Do not interchange fuel hoses. The arrows on the fuel filter indicate the direction of fuel flow.
Start the engine. The removal of air from the fuel occurs automatically when the engine is started.
Visually check that there are no fuel leaks, especially at the hose connections to the fuel filter.
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