Fuel filter (1.8 l injection diesel) — removal and installation

Special tool

Hand vacuum/pressure pump 23-036A (416-D001)

Withdrawal

1.

WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related items. In such situations, there are always highly flammable mixtures that can ignite. Failure to follow these instructions may result in injury.

CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and very close clearances. Therefore, it is especially important to observe absolute cleanliness when working with these elements. Always insert plugs into any open holes or lines.

Disconnect the ground wire from the battery. See Section 414-01 for more information.

2. Clean the area around the fuel filter and fuel line connections.

3. Disconnect the return line from the fuel filter from the fuel pump to the fuel filter. See Section 310-00 for more information.



4. Disconnect from the fuel filter the feeding fuel line going from a fuel tank to the fuel filter. See Section 310-00 for more information.




5. Disconnect from the fuel filter the feeding fuel line going from the fuel filter to the fuel pump. See Section 310-00 for more information.

• Install the plug on the fuel supply line of the fuel pump.

6. Remove the fuel filter mounting bracket and fuel filter.

• Press the clip on the fuel filter mounting bracket.

7. Remove the fuel filter from the fuel filter mounting bracket. Loosen the screw.

Installation

1.

WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related items. There are always highly flammable mixtures that can ignite. Failure to follow these instructions may result in injury.

CAUTION: Diesel fuel injection equipment is manufactured to very precise tolerances and very close clearances. Therefore, it is especially important to observe absolute cleanliness when working with these elements. Always insert plugs into any open holes or lines.

NOTE: Make sure the fuel filter is properly installed on the fuel filter mounting bracket.

Install the fuel filter to the fuel filter mounting bracket.

• 1. Align the position of the fuel filter according to the mark on the fuel filter mounting bracket.
• 2. Tighten the screw.

2. Install the fuel filter and fuel filter mounting bracket until you hear a click.




3. Clean the area around the fuel filter and fuel line connections.

4. Remove the plug from the fuel filter and connect the fuel supply line from the fuel tank to the fuel filter to the fuel filter.

• Discard the plug as it is no longer needed.

5.

CAUTION: Use a new piece of clear plastic tubing with the special tool.

CAUTION: Make sure that the fuel filter connection is not damaged when installing the special tool, as this can cause air to enter the fuel lines.

Remove the plug from the fuel filter and, using the special tool, prime the fuel filter until clean fuel flows into the vacuum pump reservoir.

• Discard plugs as they are no longer needed.

6. Remove the special tool.


7. Remove the plug from the fuel supply line from the fuel filter to the fuel pump and connect the fuel supply line from the fuel filter to the fuel pump to the fuel filter.

• Discard the plug as it is no longer needed.

8. Remove the plug from the fuel filter and connect the fuel return line from the fuel pump to the fuel filter to the fuel filter.

• Discard plugs as they are no longer needed.