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Go Back   TDIClub Forums > TDI Model Specific Discussions Areas > VW MKV-A5 Golf/Jettas

VW MKV-A5 Golf/Jettas Discussions area for A5/MkV Jetta/Golf (2005/2006 PD and 2009 CR).

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Old February 14th, 2011, 14:04   #1
CMB430
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Default Came Home On the Hook TWICE Today!

How I spent my weekend: http://forums.tdiclub.com/showthread.php?t=308001

Today, was another story. This morning it started off great. I did my running around and on the way home I got caught at a red light. When it turned green I started to go and my ESL kicked it! There is NO ice on the road today...it is in the high 40's. I look in my mirror and see a puddle and my drive wheel is not grabbing. I pull off the first chance I get and turn off the car. I pop the hood and there is diesel EVERYWHERE and it ran down the RF tire and all over the place. I call AAA and have it towed to my house. I find that it is the filter housing. I pull the top off and see that the green gasket looks like it did not seat properly. I pull a new one out of the box and install it...checking the torque specs (44 in-lb IIRC) and set it in place. I washed the diesel off of everything and used brake cleaner on the RF to make sure all the fuel was off.

I decide to go get fuel and make sure all is well. The car had been idling for over 40 min at this point, just to make sure the leak did not come back and to dry off all the water. I go get fuel and decide to wash it...so I am in line at the car wash. I see smoke start to come out from under the hood! I shut off the car and get out...it is diesel again. I move out of line and pull into the parking lot. AAA will not pay for this tow unless I take it to a repair shop because it is the same problem. So they call a tow for me and I pay out of pocket to have it brought home.

I called the dealer and of course they do not stock the fuel filter housing. So for $299 plus tax it will be there for me on Wed. I figure I must have either bent the cover, stretched the torx screws (did not have the manual first time I changed the filter so I guessed on the tightness) or Murphy is just a prick.

So that was my Love Day. I assume I can reuse the hoses and clamps for the fuel lines on the new fuel filter housing when I install it. It burns my a** that I have to put more money into the car. The other money spent was to keep it nice...this should not happen but I do not think it was VW's fault.

Is there anything that, when I took the battery out to clean the tray and change the brake fluid, that could have caused the fuel pressure to change by chance? Could the filter housing not be out of spec, but experiencing higher than normal pressure?
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Old February 14th, 2011, 15:55   #2
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Your post implies that the leak is between the top and the FF hounsing. Is that correct? If so, can't you just replace the the top, assuming that it's somehow bent? I would think that you couldn't deform the ff housing (isn't it cast aluminum?). Of course, the obvious issue would be a deformed gasket, but I assume you've already checked that.
Just a thought. Sorry for your trouble.
As for changing the fuel pressure, I can't believe that moving the lines around a bit could change the pressure.
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Old February 14th, 2011, 16:04   #3
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Hello fellow NVA diesel owner. How about that fuel price? I cried when I saw it running on the road...not once but twice. To answer your questions, I find it hard to believe that 2 gaskets could be bad. The part I ordered is the assembly, not just the top, so I will replace the lid and canister. That is where the leak is. Right where the lip / pry point is on the front facing the headlight. It sprayed between those two screws.

Those tires are still running great.
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Old February 14th, 2011, 16:42   #4
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I think that your fuel return line must be plugged up or something.

The pressure in that fuel canister should only be about 10 psig.

It sounds as if you are building back pressure when your system has high return flow.

Did you remove any hoses from your top?

Are you positive that you are putting your fuel filter in properly? Do you have the two hole or the single hole filter?
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Old February 14th, 2011, 16:53   #5
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I removed no hoses from the filter housing lid when I changed the filter. I have the filter that uses the blue gasket with 4 or 5 holes on top. I replaced all 3 parts plus the silver washer for the top screw that is used to drain the fluid on older models per the Bentley manual. None of the hoses look collapsed or anything and I did not kink them.

I am not an expert VW mechanic but I went to school for automotive tech for 2 years and was a mechanic in the Army...so I have a good idea of what right is.

Your idea of pressure sounds plausible. The first time the fuel started while I was stopped after driving at about 45 mph for 2 miles and slower around town before that. The engine was warm. It did NOT leak one drop while idling for 40 minutes in my driveway nor did it leak on the 5 mile trip to the fuel station as I looked when I stopped to pump. It started after I drove in 2nd gear around the building to the car wash and was stopped in line. Is there any connection?
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Old February 14th, 2011, 17:04   #6
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There is a nipple on top of the filter that must align with a dimple in the top of the fuel canister. This is easy to miss, and if it is not aligned properly perhaps the return line can get blocked?
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Old February 14th, 2011, 17:06   #7
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Is the gap around the top flange evenly drawn down all the way around?
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Old February 14th, 2011, 17:08   #8
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Okay. The Dealer said when I ordered the part there was no return since it is a special order...I find it hard to believe that half of what I order from them (belt, fog light bulbs to name a few) are special order, but it is what it is. So either way now I am replacing the housing as I just may have messed up the screws on the first change at 20K. I cannot answer your question, but I do not remember taking notice of exact positioning of the filter in relation to the lid. Thanks for the tip and on Wed I will be sure to line it up exact.
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Old February 14th, 2011, 17:40   #9
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PM sent
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Old February 14th, 2011, 18:26   #10
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Remember, the top fuel canister seal is installed on the lid not the canister body as it appears in the Bentley manual. Found this out the hard way myself. Went for a drive and started shooting diesel out after about 20 min.
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Old February 14th, 2011, 18:29   #11
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Oh yeah, always use petroleum jelly (Vaseline) on all seals in a fuel system including the one for the fuel filter.
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Old February 14th, 2011, 20:43   #12
Mike in Anchorage
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I also had this happen with my 20 k mi service & filter replacement. In the summer, I have no reason for the ESL to turn on, but it was amazing how slick the tire got sitting at one red light and how much fuel ended up on the parking lot pavement!

If you have not checked the alignment as specified by DanG144, you'll get this mess. If that's all it is, you have not damaged anything and you can reset & go. Cleaning up that mess is not fun.
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Old February 14th, 2011, 20:51   #13
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Quote:
Originally Posted by lou95gts View Post
Remember, the top fuel canister seal is installed on the lid not the canister body as it appears in the Bentley manual. Found this out the hard way myself. Went for a drive and started shooting diesel out after about 20 min.
Did you do this?

The huge O-ring goes on the LID and then the lid is installed on the canister body. Lube the O-ring with diesel fuel.

Bill
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Old February 15th, 2011, 03:51   #14
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Yes, that's correct.
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Old February 15th, 2011, 13:49   #15
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Well, I f***ed that up. I put the seal inside the canister, positioned it as best I could then slowly tightened down the lid. When I took the old one out, it was not on the lid. I suppose that is why I did it that way. I am not able to remember what I did the first time...but what ever way it was it worked. I will make sure the new seal is wet (like any oil filter gasket/o-ring/seal) and install it on the lid. Since VW will not take the part back, I will just replace the whole housing.

My main thing is...can I reuse the hoses and, mainly, clamps, that feed / remove the diesel from the fuel filter canister? Or, do they have to be replaced?
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