Filter element replacement
1. Disconnect the wire terminal «masses» (-) from the battery.
2. Remove the air filter.
3. Place a container under the fuel filter to collect fuel.
4. Remove the vent plug next to the fuel filter cap.
5. Unscrew the drain plug on the filter housing and drain the condensate into a container (see illustration).
5.5 Unscrew the drain plug 1 on the filter housing and drain the condensate into a container. The filter cover is fixed with four bolts 3
Hose 2 can be connected to drain the condensate. If the vehicle does not have a warning light for the level of condensate in the fuel filter, then the condensate is drained every 10,000 km.
6. Turn away bolts of fastening of a cover of the fuel filter and remove a cover.
7. Remove the filter element 3 from the filter housing together with the sealing ring (see illustration).
5.7 Fuel filter elements.
1 - cover bolt
2 - fuel filter cover
3 - replaceable filter element
4 - drain plug
8. Remove all o-rings because they must be replaced with new ones (see illustration).
5.8 Remove filter element 1 and O-ring 2
9. Clean the fuel filter housing and install a new replacement filter element.
10. Close the filter housing with a cover and tighten the cover fastening bolts.
11. Screw in the drain plug at the bottom of the fuel filter housing.
12. Replace the air filter and connect the wire terminal «masses» (-) to the battery.
13. Remove air from the fuel system.
Attention! Air from the fuel system must be removed in cases where the system was opened.
To remove air, unscrew the drain plug. Put a hose on the drain pipe, lower the free end of it into a container that is placed under the fuel filter.
14. Bleed the system by pushing the manual priming lever about 20 times until clean fuel comes out of the hose, free of air bubbles (see illustrations 5.14 and 5.14a).
5.14 Location of lever 1 for manual fuel pumping, plug 2 for vent hole and drain hole 3
5.14а Location of lever 1 for manual fuel pumping on XUD9 engines
15. Screw in the vent plug and remove the hose from the nozzle.
16. Start the engine and let it idle until the engine has stabilized.
17. Stop the engine and then start again. Leave the engine idling and do not press the accelerator pedal to make sure that air has been completely bled from the fuel system.
Condensate drain
Attention! It is recommended to make it a rule to drain accumulated condensate from the fuel filter at each oil change. After draining the condensate, the fuel system must be bled to remove trapped air. Some models have a fuel filter condensation level sensor that is connected to a warning light on the instrument panel. If the amount of accumulated condensate reaches a certain level, the light will turn on.
18. Remove the air filter.
19. Remove the vent plug.
20. Place a container under the fuel filter to collect condensate.
21. Remove the drain plug and drain the condensate into a container. Drain the condensate until clean fuel comes out of the fuel filter.
22. Screw in the drain plug.
23. Bleed the fuel system.