Fuel Filter Replacement in a nutshell:
1) Replace every 20K miles (I do mine every 10K with oil change).
2) Have the right filter for your housing.
3) Engine OFF! Remove Upper Sound Absorber Panel.
4) Water Separator Service (1 Screw Plug, 1 Washer Seal)
a. Remove Screw Plug and old Washer Seal with Torx T30 bit.
b. Siphon water at bottom of Filter Housing from top of housing – A.K.A Fuel Sump.
c. Siphon enough fuel to avoid spillage when Housing is opened.
d. Reinstall Screw Plug with New Washer Seal. Torque 3 Nm (27 in-lb).
5) Fuel Filter Replacement (1 Filter, 2 Seals on Filter, 2 Seals in Housing)
a. Remove 5 Torx T30 Bolts and lift off Upper Filter Housing with lines undisturbed.
b. If you see any amount of metal particles TAKE THE CAR TO A PROFESSIONAL! You have a major issue.
c. Pull out old Filter and Seals in Housing.
d. Clean as necessary Lower Filter Housing by Siphoning out remaining Water/Fuel.
NOTE: Removal of Lower Filter Housing is not a requirement. So long as you remove any contaminants found at the bottom of the canister by other means.
e. Install New Filter and New Seals.
f. FILL CANISTER WITH CLEAN FUEL to help purge air. (approx. 650 ml or 22 oz) —OR— Use VAG-COM to operate fuel pump from fuel tank to prime the fuel system (the air will be sent back to the tank to vent) SEE VAG-COM STEP BELOW (7).
g. Reinstall Upper Filter Housing and secure with 5 Bolts. Torque 5 Nm (44 in-lb).
6) Reinstall Upper Sound Absorber Panel.
7) If you have VCDS/VAG-COM, operate fuel pumps to purge air from Filter Housing.
8) Otherwise, Start Engine & try to run it at 2K RPM for at least 30 seconds. If Engine shuts down, restart engine (this method is not preferred. it is bad for your High Pressure Fuel Pump).
NOTE: Turning key to turn on Accessories does not turn on the fuel pumps, from what I have read, only when the key is turned to Ignition (Engine Start).
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A visual aid to what to expect when replacing the Fuel Filter on the 2009 VW Jetta TDI (A5 – CBEA ).
I used as a reference the Bentley Publishers VW Jetta Service Manual (2005-2010) as well as a couple of very good write-ups which can be found at the following links. Many thanks to those who took the time to document and share the information at these links.
https://www.myturbodiesel.com/1000q/a5/2009-2010-VW-TDI-fuel-filter.htm
https://www.tdiblog.com/tdi-do-it-yourself/replacing-fuel-filter-a5-brm-cbea/#more-148
I obtained the Mann Fuel Filter from IDPARTS.COM (formerly TDIPARTS.COM), UPS Ground Shipping was free with them. Amazon.com also offers the same Mann Fuel Filter for those who are exclusive to Amazon.
Post time: Sep-03-2017