Fuel Cooler

Fuel Cooler

• The fuel cooler is located at the front of the engine compartment, on the left side behind the fuel filter.

Special tools, testers and auxiliary items required

• Hose Clip Pliers (V.A.G 1921)

• Hose Clamps Up to 25 mm Dia. (3094)

• Drip tray

Removing

Follow the guidelines for cleanliness. Refer to => [ Clean Working Conditions ] Fuel Supply System.

Risk of scalding due to hot steam and hot coolant.

• The coolant system is under pressure when the engine is warm.

• Cover the coolant reservoir cap with a cloth and then open it slowly to release the pressure in the system.

- Open the cap on the coolant reservoir.

- Remove the fuel filter from the bracket, the fuel hoses remain connected to the fuel filter. Refer to => [ Fuel Filter, Vehicles with Vertical Fuel Filter ] Fuel Filter, Vehicles With Vertical Fuel Filter

- Place a clean cloth under the separating location to catch any fuel that may leak out.

Very hot fuel can burn skin.

• In extreme cases, the fuel lines and the fuel itself in vehicles with a common rail engine can be as hot as 100 °C (212 °F) after the engine has been turned off. Let the fuel cool down before opening any line connections otherwise there is a danger of scalding.

• Wear protective gloves.

• Wear safety glasses.

There is a risk of injury because the fuel is under pressure.

• To reduce pressure in the fuel system, lay a clean cloth around the connector and carefully loosen connector.

- Remove the fuel return hose - 3 - from the fuel cooler and the fuel filter with the hoses still connected and lay them to the side.






- Disconnect the coolant hoses - 1 and 2 - with the (3094) and remove them from the fuel cooler.

- Remove the fuel return hose - 6 - from the fuel cooler.

- Remove the bolt - 5 - and the fuel cooler - 4 -.

Installing

Install in reverse order, paying attention to the following:

• For the correct tightening specifications, refer to => [ Fuel Cooler Overview ] Fuel Cooler Overview.

• Secure all hose connections with spring-type clamps appropriate for the model. Refer to the Parts Catalog.

- Install the fuel filter. Refer to => [ Fuel Filter, Vehicles with Vertical Fuel Filter ] Fuel Filter, Vehicles With Vertical Fuel Filter.

- Fill with coolant and check the level.