Volkswagen Cars 2000-05

Removal & Installation

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Most vehicles use a fuel filter mounted under the vehicle, below the fuel tank. An arrow should be on the filter indicating fuel flow direction. Install with arrow pointing to engine. Use care not to mix up fuel supply or return lines. Fuel pressure applied to the return side of the system will cause damage.

In addition, some vehicles use a filter in the engine compartment near the fuel distributor. If equipped, use the following procedure:

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Make certain to follow the precautions and relieve fuel the pressure.
  4.  
  5. Disconnect the fuel lines leading into and out of the fuel filter.
  6.  
  7. Unscrew the filter retaining bracket and remove the filter.
  8.  
  9. Install a new filter in the bracket and reattach the bracket. Be sure the arrows are pointing in the direction of the fuel flow.
  10.  
  11. Reconnect the fuel lines, start the engine and check for leaks.
  12.  



Click image to see an enlarged view

Fig. Always use a back-up wrench to hold the fuel filter when loosening or tightening the fittings

The fuel filter removes particulate matter from the fuel system that might clog the small orifices of the fuel distributor on CIS-E equipped vehicles or restrict the fuel injectors. According to the manufacturer, unless the fuel system is damaged or contaminated, the filter is large enough to handle all normal fuel filtering requirements for the life of the engine. However, changing this filter more often than recommended can ease the load on the fuel pump, especially on higher mileage vehicles.

The fuel filter is under the car next to the fuel pump reservoir and looks like a large, metal container. Arrows point the direction of fuel flow through the filter. Banjo type fittings with copper gaskets connect the fuel lines to the filter. Always replace these gaskets with the original copper type gaskets any time the fittings are loosened.


CAUTION
NEVER smoke when working around gasoline! Avoid all sources of sparks or ignition. Gasoline vapors are EXTREMELY volatile! Fuel filter replacement will cause a small fuel spill. Make sure the work area is well ventilated, wear eye protection, and observe appropriate fire safety precautions.

  1. Relieve the fuel system pressure.
  2.  
  3. Raise and safely support the rear of the vehicle. Have a pan ready to catch the fuel that will unavoidably run out.
  4.  
  5. Have a rag handy and wear safety glasses when loosening the fittings. The system will be under pressure and fuel will be sprayed.
  6.  


NOTE
Due to the confined space between the filter and the fitting, it may be necessary to obtain a thin open end wrench, or before opening the fuel system, thin one as necessary on a suitable grinding wheel.

  1. Hold the filter as necessary with a 19mm or 22mm wrench and loosen the fittings with a 17mm wrench. If space permits, use a flare type wrench. Wrap the filter and wrenches with a rag to contain any pressurized fuel. Have the catch pan ready.
  2.  


NOTE
Always use a back-up wrench to hold the filter, or the fuel lines may be damaged.

  1. Disconnect the fuel lines, loosen the mounting bracket and remove the filter.
  2.  
  3. Install the new filter but Do NOT tighten the mounting bracket yet.
  4.  
  5. Make sure all fittings and sealing surfaces are clean. Install the banjo bolts with new copper gaskets and torque to 14 ft. lbs. (20 Nm).
  6.  


NOTE
After replacing the fuel filter, it may take several attempts to start the engine. This is because the fuel loop between the fuel pump and the fuel injectors must purge itself of the air that has entered the system when the filter was removed. For safety reasons, the fuel pump only operates when the engine is rotating.

Most vehicles use a fuel filter mounted under the vehicle, below the fuel tank. An arrow should be on the filter indicating fuel flow direction. Install with arrow pointing to engine. Use care not to mix up fuel supply or return lines. Fuel pressure applied to the return side of the system will cause damage.

In addition, some vehicles use a filter in the engine compartment near the fuel distributor. If equipped, use the following procedure:

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Make certain to follow the precautions and relieve fuel the pressure.
  4.  
  5. Disconnect the fuel lines leading into and out of the fuel filter.
  6.  
  7. Unscrew the filter retaining bracket and remove the filter.
  8.  
  9. Install a new filter in the bracket and reattach the bracket. Be sure the arrows are pointing in the direction of the fuel flow.
  10.  
  11. Reconnect the fuel lines, start the engine and check for leaks.
  12.  

Gasoline Engines





Click image to see an enlarged view

Fig. Always use a back-up wrench to hold the fuel filter when loosening or tightening the fittings

The fuel filter removes particulate matter from the fuel system which might clog the fuel distributor block or fuel injectors. According to the manufacturer, unless the fuel system is damaged or contaminated, the filter is large enough to handle all normal fuel filtering requirements for the life of the engine. However, changing this filter more often than recommended can ease the load on the fuel pump, especially on higher mileage vehicles.

On gasoline engine-equipped vehicles, the fuel filter is under the car next to the fuel pump reservoir and looks like a large, metal container. Arrows point the direction of fuel flow through the filter. Banjo type fittings with copper gaskets connect the fuel lines to the filter. Always replace these gaskets any time the fittings are loosened.


CAUTION
Never smoke when working around gasoline! Avoid all sources of sparks or ignition. Gasoline vapors are EXTREMELY volatile! This procedure will cause a small fuel spill. Make sure the work area is well ventilated, and observe appropriate fire safety precautions.

  1. Relieve the fuel system pressure.
  2.  
  3. Raise and safely support the rear of the vehicle. Have a pan ready to catch the fuel that will run out of the reservoir.
  4.  
  5. Have a rag handy and wear safety glasses when loosening the fittings. The system will be under pressure and fuel will be sprayed.
  6.  
  7. Hold the filter with a 19mm or 22mm wrench and loosen the fittings with a 17mm wrench. Wrap the filter and wrenches with a rag to contain any pressurized fuel. Have the catch pan ready.
  8.  


NOTE
Always use a back-up wrench to hold the filter, or the fuel lines may be damaged.

  1. Disconnect the fuel lines, loosen the mounting bracket and remove the filter.
  2.  
  3. Install the new filter but do not tighten the mounting bracket yet.
  4.  
  5. Make sure all fittings and sealing surfaces are clean. Install the banjo bolts with new copper gaskets and torque to 14 ft. lbs. (20 Nm).
  6.  


NOTE
After replacing the fuel filter, it may take several attempts to start the engine. This is because the fuel pump needs to operate (while the engine is cranking) to pressurize the fuel system.

 
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