Replacing the Fuel Filter

Step by Step

by
Chirpz

www.chirpz.com
Purchase a filter and compare it with the old one.
Make sure there are two small O-Rings included in the box.
You can compare without removing the old filter.
Tools: Ratchet, 10mm socket, phillips and blade screw drivers,
metric allen wrench, metric torx socket (8mm I think), small hook tool.
As always, before starting, disconnect your negative battery cable.

See my note
later about
removing the
original hose
clamps
Remove the fresh air intake.
Loosen two screws and remove
one bolt, then wiggle it off.
Be careful to keep foreign
objects from entering your
turbo or the air tube.

Bolt

Screws
Remove the end of the air tube from the air box and then rotate the tube
upward. Then wiggle it off of the turbo inlet.
Fuel filter is
located down
here!

My Elephant Hose
Mod
 Loosen this Allen Screw
Remove two hose Clamps
and remove the hose ends.
Fuel Filter

Remove Torx
Screw that holds
a thin wire.
If you still have the original hose clamps on the hoses, you will have a hard
time. To remove them requires a special tool. I cut mine off using a
Dremel Tool with a cutting wheel. It was delicate but easy. The trick is
to not damage the hoses. I replaced the original clamps with standard
screw type hose clamps.
 With the small wire removed
you can wiggle the filter and
harness upward a little. This
makes it easier to remove
the plug

Squeeze the small tab on the

plug and wiggle the plug
off of the filter. There is only
one tab.
 Remove two screws that hold
the water sensor

Carefully rotate the water sensor

clockwise until it clears the
mounting bracket. This is a
fragile part so be gentle. It is
all one piece.
To remove the water sensor you must pull it straight up but it fits very
tight. Use your screw driver alternately on each side and pry very
gently as you wiggle the sensor in slight rotations. It is held by the
tension on the O-Rings. Break it and you win a trip to the dealer.

Notice the thumb screw and

hose cock. When you get
the “water in fuel” message
you can hook a small
aquarium hose to the cock
and run it down to a container.
Loosen the thumb screw,
and turn on the engine for
a few seconds. Fuel will
jet out of the hose and into
your container. This removes
the water.

It is easier to use a diesel

fuel additive now and then.
 Remove the two O-Rings
and replace them with the
new ones. I use a small
hook tool to do this.

Water sensor with

evacuation valve

O-Rings
Carefully wiggle the water sensor back into place and replace
the two screws. It is a tight fit. It helps to moisten the O-Rings
a little with some fuel from the old filter.
It is probably a good idea to
prime the filter with some fuel.
You could pour the fuel out of
the old filter into the new before
you insert the sensor. I have
never done this but it has been
suggested by others to prevent
your injectors from gulping air.

New filter with sensor in place

I remove this packing.

Re-assemble in reverse order. Before you replace the air intake, make sure
there is no trash or tiny creatures hiding inside. Inspect your gasket and
replace it if necessary. You can see I still have the old cruddy orange gasket.
If your turbo and seal are dripping with CCV oil, consider doing the
elephant hose mode in the near future.

Crank the engine and inspect

the hoses for leaks. It may take
longer than usual for the engine
to crank.