VW TDI cabin air & fuel filter replacement

Replacing the cabin air filter and fuel filter in my 1997 Volkswagen Passat TDI diesel... or at least trying to. It seems I got a defective fuel filter. No amount of priming and purging the fuel lines could get the engine started and running with the new fuel filter; it must've had an air leak somewhere. I reinstalled the old filter and within a few cranks the engine was purring like a kitten. I noticed the new one was made in Spain instead of Germany, so maybe even MANN is cheapening out these days...

Anyway, the instructions I give are valid for any Mk3 Golf/Jetta, B4 Passat, or pre-2004 Mk4 Golf/Jetta TDI diesel. Older non-TDI diesels are similar as well, although diesels prior to 1989 do not have the thermostatic valve (held in by the clip) and extra fuel lines which cycle fuel through the injection pump and back into the fuel tank in cold weather to help keep the fuel from gelling. Also not all Mk3s came from the factory with a cabin air filter, although you can buy the housing to retrofit one into your car if it doesn't have it.

Category:

Autos & Vehicles

Tags:

• vw
• volkswagen
• tdi
• diesel
• engine
• 1.9
• 1.9l
• turbo
• turbocharged
• cabin
• air
• pollen
• filter
• hvac
• fuel
• replace
• replacement
• change
• changing
• how-to
• instructions
• tutorial
• help

[Kbrusky15]

This is about the time that VW started to actually implement some sort of sound deadening in their vehicles right...? I hope..?

[vwestlife]

@Kbrusky15 The B4 Passat is a relatively quiet car, and is comfortable to drive on the highway. My sister's 1996 Golf was too.

There is supposed to be a plastic engine cover with some foam insulation underneath it, but my Passat didn't come with it (the previous owner probably lost it or threw it out). Also there is an insulated belly pan under the engine.

[ethanM088]

hey man i found this video very helpfull, but do you know how to replace the air intake box? because on vws its way more compalacted than your avrage car lol id very very much aprieatate it if you maybe put up a vido about that thanks, :)

[vwestlife]

@ethanM088 Do you mean the while air filter housing, or just the filter element inside it? The cover is held on by four metal snaps. You pull up on the snaps to unlatch them, then the cover can be lifted up to gain access to the air filter.

[Alifun7]

Hey, you just saved me a 100+ bucks. Thanks

I am on 2000 Jetta TDI.

Just had replaced cabin filter for now. Air in car feels cleaner.

How does fuel filter replacement helps the TDI in general?

[vwestlife]

@Alifun7 Badly clogged air and fuel filters reduce your fuel economy and engine performance. The quality of diesel fuel is better than it used to be, but you still need to change the fuel filter once every few years. If you're really curious, you can cut open the old fuel filter and see what kind of debris it had collected.

[BLK20V]

Thank you the useful guide, it was very helpful and it all worked out for me in the end, eventually the polo came back to life with the new fuel filter in, it was a BOSCH filter mind you : )

[an65001]

@TheMeza81 This is for a diesel, not for a gasoline.

[p8rsn]

DO NOT fill the new filter with fuel additive!!! The clue is it's called "additive" therefore doesn't combust very well on it's own. ALWAYS fill the filter with fresh diesel!

[ArvinRedlineexpress]

nice video, thanks for sharing. now i know how to tackle the job.

[TheMeza81]

I have a 1996 jetta gls 2.0 and it eats alot of gas anyone help me?

[the4000class]

I just changed the fuel filter in my 01 jetta tdi it ran fine until the next morning. It will turn over but not start. A mechanic at my work told me the reason it would not start was because there was air in the line. So if it will not start then there may be air in the line . to get the air out crank the engine to get the air out of the line.

[motojoe422]

You did pretty good for only using one hand for the most part. thanks for your help. I have a 1992 jetta non turbo diesel. The previous guy converted the fuel filter setup to a 2000 tdi, it is alot cheaper for the filter and is apparently easier to replace. thanks

[nam111111111]

Fuel treatment did not help starting you should of mixed it, for the money just stick to gen filters there not much more.

[carswesty]

i used to work for a filter manufacturer & believe it or not 1 in every 500 filters was defective due to warped 'O'ring seats ect ect! so he may have just got that 1 in 500 on this occasion! & diesel cleaner will burn straight from the filter,it designed to do that has it's diesel based with cleaning agents in it!

[supersesqui]

Very well done.

DONT put anything other than fresh fuel in the filter......as you found out lol

But get a friend to do the camera work for you to make it easier.

thank for vid.