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Standard Disclaimer: This article has been prepared for informational purposes only. You voluntarily assume all risks, known and unknown, of any injury or damage, however caused, even if caused in whole or in part by the action, inaction, or negligence of any party. Perform at your own risk.

Introduction
The High Pressure Fuel Pump (HPFP) is prone to failure on the Jetta 6 TDI (CJAA). It's failure is characterized by metal particles collecting in the Fuel Filter and remaining in the diesel fuel in the Filter Housing. Careful examination of the Filter Element, residual fuel, and Filter Housing must be made to check for metal particles.

If any are found, high resolution photographs should be taken, metal laden paper towels from cleaning the Filter Housing should be saved, and the metal laden Filter Element should be saved as well. These can then be used to support a warranty claim for HPFP failure.

The Fuel Filter should be changed every 30,000 kms for the Jetta 6 TDI CJAA engine. Since the HPFP is prone to failure, Priming the Fuel System must be performed after the Filter Element change to ensure that the HPFP is never run dry. Poor lubricity is known to cause HPFP failure.

Work in a well ventilated clean area. Because the fuel system will be opened, do not work in a dusty environment. Do not open the Filter Element package until it is ready to be installed. The Filter Element and "O" Ring must be clean when installed.

Parts & Tools
Fuel Filter Kit (Filter Element - PU 936/1, 1K0 127 177 B and "O Ring") - 1K0 127 434 B
7' Rope or 32" Bungee Cord
T30 TORX
10mm Socket & Long Extension
Ratchet
Magnet
Pry Tools






Procedure





Release the fuel hoses from the retaining clip.




Surround the Filter Housing with rags. Remove the five T30 bolts on the Filter Housing Cover. Carefully pry the Filter Housing Cover without gouging or deforming the Filter Housing lip or the Filter Housing Cover. Work the pry tool around the Filter Housing Cover to evenly release it.




Raise the Filter Housing Cover enough to allow your other hand to grasp the Filter Element to twist it free from the Filter Housing Cover. Allow diesel in Filter Element to drain back into Filter Housing. Wipe any diesel that may drip. Do not allow diesel to remain on rubber hoses or belts.




Elevate the Filter Housing Cover above the fuel lines to retain fuel in the lines. Run a rope or bungee cord to the hood latch hook to keep the Filter Housing Cover in the proper position. Wipe any diesel that may drip. Do not allow diesel to remain on rubber hoses or belts.




Release the clip from the Filter Housing. Use a pry tool on the left and right sides of the clip to release it.






Release the two 10mm bolts and single 10mm nut to remove the Filter Housing. Use a magnet to remove the 10mm nut. Run the remaining fuel through a paper coffee filter, then pour it back into the fuel tank. Clean the Filter Housing and inspect for metal particles.

Remove the "O" Ring from the Filter Housing Cover and install the new one.

Reinstall the Filter Housing. Torque the 10mm fasteners to 8 Nm/5.9 ft lbs.

Lubricate the Filter Housing Cover "O" Ring with clean diesel. Lubricate the green Filter Element seal with clean diesel. Lubricate the "O" Ring contact point of the top of the Filter Housing with clean diesel. Insert the Filter Element into the Filter Housing and hold it while the Filter Housing Cover is mated to it.

Press the Filter Housing Cover firmly and evenly until it is correctly seated in the Filter Housing. Reinstall the Filter Housing Cover T30 bolts by hand. Then tighten them in a diagonal star pattern to ensure uniform pressure and seating of the "O" Ring.

Torque the T30 Filter Housing Cover bolts to 9 Nm/6.6 ft lbs.

Prime Fuel System
1.) Go to "01. Engine" in VCDS.
2.) Click "Basic Settings - 04"
3.) Enter "35" in the "Group" Box and click "Go!"
4.) Click the "ON/OFF/Next Button". Run the fuel pumps for 30 seconds, then click the "ON/OFF/Next" Button to stop the fuel pumps.
5.) Rest the fuel pumps for a few minutes to avoid taxing and overheating them. Check the Filter Housing Cover for leaks.
6.) Repeat step 4 & 5 two more times for a total of three times.
7.) Start engine and let run at moderate speed for a few minutes, then switch off. Road test the vehicle at full throttle at least once and check for leaks.

Note: If there is any air left in the fuel system, the engine may switch to limp mode. Switch off the engine and clear the fault memory. Then continue road test.



 
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