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Old November 29th, 2011, 19:03   #1
DanG144
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Default Improved fuel filtration water separation Water in Fuel alarm for PD and Common Rail

2 Micron Caterpillar fuel filters went on my cars as soon as I bought them.
But I wanted a water separator and water in fuel alarm.

I recently added some fuel filters to my 2005 Jetta BEW PD, as a test bed for ultimate installation on my 2010 (well my wife's 2010) Jetta Sedan CJAA.

I ran 3/8" fuel line to a pair of WIX 24770 filter bases, through a 30 micron WIX 33367 "mud" filter(changing to 20 micron FS1212 - a much better water separator) with a water drain, then through a 7 micron Fleet Guard FS19596 secondary filter with water drain and Water-in-Fuel sensor on it. A 3/8" line runs back to my Lubrication Specialist's MkIV 2 micron Caterpillar filter.

The filter head is mounted outboard the left frame rail, just in front of the left front tire, right behind the horns. Remove the bumper cover, drill 3 holes, use self tapping machine screws - mounted in 30 minutes. Most of which was spent trying to get to the bolt heads to tighten them. I plan to make access points from under the fender for easy access to periodically drain the filters.

The PD fuel system puts out about 9 psig at idle, out of of the filter set up to the tandem pump. As engine speed at full throttle raises to 4500 rpm, the filter system outlet pressure drops to 1.5 psig. This is the same pressure drop as the 2 micron Caterpiller filter alone - my gauges show no difference at all - though we all know it has to have some flow resistance.

I have not done flow and pressure readings on the 2010 common rail, yet.

There is a chance that I will need to add a second in tank fuel pump in order to assure positive pressure to the Aux fuel pump/tandem pump.

The WIF (water in fuel) alarm is not yet hooked up (or even bought) on my 2005 - it will be a stand alone alarm - probably just light up an LED.

I was hoping that one of you genius club members that works with 1's and 0's for a living can help me figure out how to hook it up to the instrument cluster WIF alarm that I have been told exists on the 2010 Jetta Sedan - it is just not used.

Total cost about $136.00 US. for the recent add on unit. About $125 for the http://www.lubricationspecialist.com...filter-system/ .
wix filter 33367 $7
Fleet Guard FS 19596 $38
Wix 24770 bases $42.
fittings (half inch pipe nipple by 2", two brass 3/8" barb to 1/2" mpt) $10
20 ft 3/8 fuel hose Mcmaster 54605K34 $26
Hose clamps $4

There are many other choices available. I chose to keep the same thread and base for all 3 of my filters. That way one can replace another in a pinch.


This is just a thread on what I am doing to my own cars. You are responsible to anything you do to your own car.


Last edited by DanG144; January 7th, 2012 at 15:06.
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Old November 29th, 2011, 19:04   #2
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Old November 30th, 2011, 17:37   #3
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I was hoping that one of you genius club members that works with 1's and 0's for a living can help me figure out how to hook it up to the instrument cluster WIF alarm that I have been told exists on the 2010 Jetta Sedan - it is just not used.
Great post! I have been meaning to put together a better filter system for my '10 but hadn't dived in yet. How did you decide on 2 micron - it that a typical final filter size used in the medium-heavy diesel industry? I've got some learning to do regarding hardware.

What is this WIF indicator on the instrument cluster you speak of? Does such a thing really exist? That would kinda imply VW has an WIF system available on something somewhere else in the world? That we might also check to see if it could be retrofit/adapted to the caras alternative? Just wondering...

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Old November 30th, 2011, 18:36   #4
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Actually, 99.5 cars have what looks like a water in fuel light in the gauge cluster. It had no LED behind the icon but I made it functional on mine by adding a yellow LED and a resistor(nothing is hooked up to it yet). From other members that I have talked to, we speculate VW was planning on adding a water in fuel light to the MK4 cars and then decided to scrap the idea for some reason.

The icon looks like a low fuel light with a bunch of dots under it. Really weird. Its not on any other MKIV cars that I know of, only on 99.5s.

I wonder if the MKV cars have anything similar?
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Old November 30th, 2011, 19:24   #5
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Someone else once posted that there was a non-lit, non-used, WIF indicator in the 09 and 10 models.
I cannot see it, at all, even looking around with a flashlight at odd angles.
But it is very hard to see what all the non-used indicators are.
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Old November 30th, 2011, 19:52   #6
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I decided on the Caterpillar 1R 0750, 2 micron final filter for all the reasons that it was more or less settled on by a working group back in the early days of this forum. Getting details on fuel filter ratings can be surprisingly hard to do. The data often quoted is almost meaningless. I waded through hours of very old posts before I decided to go with their choice. This filter is often still suggested as one of the finest final filters you can get in many information sources.

It is one of the finest filters available, as in for smallest particles.
It has a very good capacity.
It has a low differential pressure.
It is cheap and readily available.
An aftermarket head is available for it with the thermostatic tee from Lubricationspecialist.com. Or from nicktane without the tee. I like the tee; it maintains features designed into the Mark IV, V, and VI cars; allowing the return flow to recycle through the filter when the fuel is cold, until it warms up. This helps ensure good fuel feed on frosty mornings, and improves combustion.

The mount can be installed in minutes in the Mark IV.
On the Mark V and VI, I cut the existing canister to make a mounting spot - not quite as convenient, but it still makes an excellent mount.

I chose to keep the filter mounts for the additional pre-filters and water separators the same thread and base size as the Caterpillar 1R-0750 2 micron filter. I chose not to use the RACOR water separator filters with bowls because of the potential for additional leaks and expense.

I read for hours on boat, heavy truck, and light truck diesel filtration in several forums before making my choices. I do not doubt there are better ways to make a filter setup, but I think this one is a fairly good first effort.

The filter choices I made are readily available, though I do have to get the FS19596 FleetGuard filter separator from a Cummins source.
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Old December 1st, 2011, 06:06   #7
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You are always so good with the fuel system upgrades. Keep up the good work. Any chance of the pictures on the MKV?
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Old December 1st, 2011, 07:18   #8
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Mark V installation of 1R-0750 2 micron Caterpillar fuel filter.





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Old December 1st, 2011, 08:40   #9
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wow that's dusty in there for a 2010!!!

Do you feel that just running the Cat filter w/o water seporation would be good enough of an upgrade over the OEM Mann filters?
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Old December 1st, 2011, 09:01   #10
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Quote:
Originally Posted by turbocharged798 View Post
Actually, 99.5 cars have what looks like a water in fuel light in the gauge cluster. ...The icon looks like a low fuel light with a bunch of dots under it. Really weird. Its not on any other MKIV cars that I know of, only on 99.5s.
THAT'S what that goofy icon is for! Hmm!

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Old December 1st, 2011, 09:36   #11
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wow that's dusty in there for a 2010!!!

Do you feel that just running the Cat filter w/o water seporation would be good enough of an upgrade over the OEM Mann filters?
I do think that the Cat filter alone is a worthwhile upgrade to the Common Rails (or any VW engine) over the original filter. That is what I have run on my 2010 since 12/2009 to now.

I am not quite ready to update my 2010 with this pre filter water drain setup - more data collection will be done.

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Old December 1st, 2011, 10:34   #12
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wow that's dusty in there for a 2010!!!

Do you feel that just running the Cat filter w/o water seporation would be good enough of an upgrade over the OEM Mann filters?
I live on a gravel road. The engines look like that in a week or so.
I have to wash them before servicing each time.
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Old December 4th, 2011, 23:06   #13
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Need filter change you should update this and show exactly how/what you have the filter zip tied to. I am interested as my father plans on keeping the 09 for a while so this might be worth it.
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Old December 5th, 2011, 09:19   #14
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The only unused icon I could find was for interior monitoring. I didn't see anything that resembled water in fuel. This is just from the documentation; I don't have a real car to look at. I highly doubt there is one though.

You can, however, use a simple binary input that is already available in the cluster. The lamps are off when there is a path to common.

A few of these circuits are:
1. Brake pad wear
2. Washer tank low
3. Coolant tank low
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Old December 5th, 2011, 12:36   #15
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Jcrews,
Thanks for the input. You have a much better handle on these circuits than I do. (That is actually a mis-statement; it implies I have some knowledge of the circuits.)

One of these will be on my wife's 2010 common rail, and I am not sure a dual purpose warning would be effective for her. Or were you intending a complete high jacking of the function (now that I think about it, this seems more likely.) Even then, the simpler the better.

The circuit would have to alarm as the conductivity at the probe in the filter separator dropped to something under 200 kohms. (I have seen numbers from 150 to 180 Kohms)

Circuit design on available warning systems usually limit current flow and voltage at the probe, in order to assure no spark can be generated in a worst case scenario. While this is not a huge issue for us, misfuelings have occurred. So better safe than sorry. (Even though it would take a misfueling and a vapor space with oxygen.)

I bit the bullet and ordered a Racor RK 12870 unit which has a horn and light, for ultimate installation in the 2010. Its fuel system's potential damage due to water in fuel would warrant the continuous alarm until something was done about it.

Perhaps for my own car, I may play with the washer tank low circuit. It would certainly be a better use for it.
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