Fuel filter replacement for 2005.5-2006 Jetta TDI (pumpe
duse)
Difficulty: 2/5
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Introduction
Change the fuel filter every 20,000 miles or as needed. The Mk3-Mk4 cars all use the same fuel filter, the Mk5 cars use an entirely new style of fuel filter. Most pics from tdiclub, TerribleTdi, http://nofreerides.blogspot.com/, and other sources. Note that 2005.5 and some 2006 cars have different fuel filters, check with your vendor to make sure which style filter you have! Part of the reason was rolling changes during in production from 2005 to early 2007.
Another way to check is by the VIN number. If the last 6 digits are higher than 814063 you should have a later car which often uses the later style fuel filters, earlier cars normally use the "a" suffix filter. Also note that the "a" and "no suffix" filter are interchangeable but are slightly different. Again, the best way to determine which type of fuel filter you need is to look and see for yourself and by your VIN, so when you order a fuel filter, make sure to include your VIN! The below part numbers based on VINs seem to have some contradiction, so always include your VIN when ordering.
Parts (click links to compare current prices, some prices include shipping)
Torx screws T-30
1 VW fuel filter, see notes below to see which one you need and regardless of
what the info below says, INCLUDE YOUR
VIN when ordering since there seems to be some contradiction in VIN
numbers (click thumbnails below for larger picture)
(picture 1) illustrates a filter clamped with a bayonet clamp and a torx screw
bleeder, they often use VW #1ko 127 434. The service manual says that
periodic water draining should be done, you will probably never find
water. These were found on mostly earlier A5 Jettas.
(picture 2) shows the solid clamp housing,
you might use VW# 1k0 127 434 a, found on mostly later A5 Jettas and had
no water drain.
(picture 3) shows the fat lipped housing with
solid clamp housing, you might use VW #1ko 127 434 b. Again, check your
VIN number to be sure which filter you use.
OR
20k mile filter kits (includes other misc filters, must include VIN when ordering to confirm correct fuel filter) dieselgeek , kermatdi early A5 jetta, kermatdi later A5 jetta, metalman parts kit
Procedure
Safety disclaimer: Make sure that the car is shut off and that there are no sources of ignition, spark, or flame anywhere near the car of where fuel vapors can get to. Make sure that there is adequate ventilation to carry away any fuel fumes! Always wear diesel resistant gloves when handling diesel fuel. Wear eye protection at all times when working on your car and observe all normal safety practices. See the TOS Agreement for the full legal disclaimer.
There are 5 torx screws holding the filter housing and 1 torx screw for the
bleed point in the middle. If you fuel filter
does not have a bleed point then ignore the bleed screw part. Loosen the bleed screw to release any pressure
and then remove all 5 torx screws to remove the cover.
You can see a green seal for the housing cover, a blue "olympics
rings" seal for the fuel
filter, and a metal washer underneath the bleed screw.
If you want to empty out the fuel and clean the whole housing, there are two tabs behind it. Pull them towards the rear of the car and up to remove the whole housing.
Wrap paper towels around the fuel filter housing to catch any fuel spills. Slowly pry the old filter straight up with two flat screwdrivers. I recommend using screwdrivers because if you try to pull it by hand, it will suddenly pop out. Always wear eye protection at all times when working on your car.
Slowly push the new filter into the fuel filter housing. If you push quickly, it will squirt fuel out of the bottom of the housing.
Replace the blue fuel filter seals and green filter cover seal. Note
that the blue "olympic rings" fuel filter seals will only correctly fit into the recessed
housing one way.
When tightening the filter cover, tighten them hand tight at first, then gradually in a star pattern, much like you would tighten wheel lug nuts. This method will help avoid pinching the o-rings and causing a leak.
If you have an early filter with the bleed screw, check that the bleed screw on the top and the 5 torx screws are tightened properly to 2.2 ft- lbs. This is 27 inch lbs or 3 NM.
If you have a later filter with no bleed screw, tighten the torx screws to 3.7
ft lbs, or 44 inch lbs, 5NM. I don't know why the service manual states
different torque settings for different filters, it's possible it's a typo.
Turn key to run position for 30 seconds.
Turn key off, then back to run position for 30 seconds. This lets the in-tank fuel pump prime the filter and fuel lines. Repeat as needed, and the car should start.
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