VW Caddy Type 2Kwith

1.9 L TDI Engine & DSG

Fuel Filter ChangeProcedure

By

Arie van der Winden

Copyright 2007 © Arie van der Winden

VW Caddy 1.9 L TDI Fuel Filter Change Procedure

9 August 2007 1

Fuel Filter Change Procedure

The following procedure shows a way of changing the Fuel Filter of a VW Caddy Type 2KN with a 1.9 L TDI Engine and a DSG Gearbox.

The procedure is for a novice mechanic.

The writer will accept no responsibility or liability for any mishaps or accidents.

You use this procedure at your own risk.

This procedure is available on my Website:

http://members.ozemail.com.au/~avdw

VW Caddy 1.9 L TDI Fuel Filter Change Procedure

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What you need to carry out this procedure:

• A 5 mm Torx bit for the Fuel Filter cover.

• A stubby screwdriver.

• A Tension Wrench calibrated in Nm (Newton Metres).

• One litre of Diesel to fill the filter housing.

• A container for the old Fuel Filter.

• Plenty of clean lint free rags.

• VW Engine Fuel Filter Element 3C0 127 434

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1. Locate the Fuel Filter

The Fuel Filter is the silvery looking device with four hose connections.

Looking from the front of the vehicle it is on the left hand side.

VW Caddy 1.9 L TDI Fuel Filter Change Procedure

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2.Put rags under the Fuel Filer Housing

The rags under the Fuel Filter Housing will prevent spilling of Fuel onto the vehicle’s painted frame work.

Biodiesel, if spilled, will eventually remove the paint.

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3. Lift the Window Washer Bottle top out of the way

The top is in the way for lifting off the Fuel Filter Top. Lift it and secure it behind the water return hose.

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4. Undo the Fuel Filter screws

Use the Torx bit for this. They come out easily.

VW Caddy 1.9 L TDI Fuel Filter Change Procedure

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5. Prise up the lid

Use the stubby screwdriver to slowly lift the Fuel Filter Top. It is held in by an “O” Ring.

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6. Remove the Fuel Filter Top

Lift the Fuel Filter Top and secure it out of the way.

VW Caddy 1.9 L TDI Fuel Filter Change Procedure

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7. Clean out the Fuel Filter Housing

Pump out the fuel and clean out the Fuel Filter Housing with clean lint-free rags.

VW Caddy 1.9 L TDI Fuel Filter Change Procedure

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8. Install the new Fuel Filter Element

Drop the new Fuel Filter Element into the Fuel Filter Housing as per the picture.

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9. Make sure it is the right way up

The hole in the Fuel Filter Element has to face up.

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10. Refit the Fuel Filter Top

Gentle push the Fuel Filter Top back in the original position.

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11. Secure the Fuel Filter Top

Refit the Torx screws you previously removed. Secure the Fuel Filter Top by alternatively tightening the screws like you do with a five stud car wheel.

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12. Replace the Widow Washer Bottle top and check all fittings

Check everything you have done and turn the starter key in the first position. You should hear the fuel pump in the tank. Leave it like this for a few minutes.

13. Check for leaks.

If there are no leaks try and start the engine. You may find it takes several attempts to start the engine. If the engine does not start at the third attempt wait a minute and try again.

If you keep cranking over the engine the centre screen in the dashboard will tell you to STOP.

You probably had too much air in the Fuel Filter and fuel lines.

14. Go through step 12 and 13 again.

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