Engine cuts out after fuel filter change TDI

[barnsy]

​​Hi all
2002 (52) Passat TDIs
I changed my fuel filter yesterday (as well as air and cabin filters). I followed instructions I found on here and a youtube video on how to and it seemed to go ok. Fired up first time, drove off, broke down after a minute. Went back through various threads and I reckon I spilled a bit of fuel out of the old filter meaning I didn't fully fill the new one, introducing some air. Following advice from various online articles, I ran through 5 20 second key cycles and it started third time (in line with what others have experienced).

However,
On the way to a friends place last night it cut out while slowing for a junction, started first go (had to crank for a while), and made the return trip with no issues. Today, went out and it cut out 3 times in a 5 minute journey, each time whilst slowing for a junction. Made the return journey no problem.

The threads I have found show plenty of people have had the initial issue, but I cant find much on subsequent engine cut outs. Air somewhere? Some kind of switch/ computer issue? I got the filter from ECP, fitment was fine, but could it be the filter itself? It doesn't splutter and misfire or anything, just cuts out with no warning at all. Any advice very gratefully appreciated as usual.

Almost forgot, had the back jacked up today to look at brakes, could this have moved a bubble or something?

Best
Barnsy

[barnsy]

I cant work out how to add the icon for question/ please help. Is that why nobody responded, or have I broken some etiquette? I'd rather know so I don't upset anyone.

Anyway, made two short (5-10 min) journeys from cold last night and it ran fine. Hopefully that's it. Got two long journeys tonight and tomorrow so fingers crossed it doesn't cut out on a slip road.

[smithy602179]

prob nobody got a remedy for your problem yet

[zollaf]

air normally clears pretty quickly on these, even fitting the filter without filling it, just cycling the ignition to run the in tank pump. once they run, thats normally it. if yours continues to cut out i would first look at the seals on the filter, just to make sure one isn't missing or one from the old filter is stuck to the housing, meaning there are 2 seals where there should be one, resulting in air being drawn in.

[Col]

Is it the older style cartridge or newer cannister style filter?

[jammy86]

Isn't there an o ring on the thermostat on the top of the filter? I vaguely remember changing something aswell as the filter when I did mine... or was that on the older engines?

And have you checked the water drain is sealed?

[barnsy]

Hi all
Thanks so much for the responses.
I'm not sure of the difference between the two filter types. The one I have comes as a sealed unit (as opposed to opening the canister and replacing just the filter itself, you have to swap out the entire unit and reconnect the lines).
There was an o ring that goes on one of the connections but I have no idea if this is to do with the thermostat? The top of the filter unit has two individual connections and a double one like this: http://img.photobucket.com/albums/v602/colin__/P2030060.jpg Picture credit Big Col? (Great oil change how-to).
When connecting the double one, I left the old o ring in place as it looked good (may have been a mistake), and I did notice there was a bit of difficulty getting the micky mouse clip back on. I did check the water drain was done up fully before fitting (assuming it’s a normal right hand thread).

I haven't had much chance to investigate further as I've been snowed under at work.
Once up to running temp, there is no problem. If, while it is still warming up, I allow the revs to drop i.e. from 2k - 1k, it cuts out and takes a load of cranking to start again. It will do this repeatedly until up to running temp (unless I keep it over 1500 revs until warm). Never had any such issues until I changed the fuel filter. By the sound of things I need to take a good look at all the seals?
It may take me a while but once I do that I'll report back.
Cheers
Barnsy

[smithy602179]

there is a fuel temp sender just below the filter ,not saying you have but just look to see if the multi plug is connected to it still and also check all the vacuum connections around the filter area too .

[Col]

Did you change both the blue and black 'o' rings?

[caldirun]

When connecting the double one, I left the old o ring in place as it looked good (may have been a mistake), and I did notice there was a bit of difficulty getting the micky mouse clip back on
Barnsy

Could be 2 O rings in place causing the difficulty with the clip and also a poor seal!