Diesel fuel filter removal

[Passatguy]

Hi everyone, very first post ... on any site... ever . Here goes.
I have a passat tdi 115 and want to change the fuel filter. I have searched the forum and seen the "how to" section but my particular issue is how to remove, what i have been told is the fuel cooler on top of the fuel filter. The Haynes manual says just unscrew the central bolt, but with what. I have been to Halfords and my local motor factors and asked them what size and type of fitting it is. A very helpful lad at Halfords tried every type of torx, allen and other key he had in the store and said that he didn't know what it was. His efforts were above and beyond the call of duty. Have looked for a tool on e bay... nothing :confused: . I have tried all of my limited collection of tools to no avail.It will not budge because i cannot get enough pressure on the bolt with a screwdriver etc. Does any kind soul know how to get this fuel cooler off with a reasonably priced tool that i can purchase, to get at the filter. :1zhelp: Any advice would be welcome.

[Passatguy]

Hi again,
Can anyone help with the above and advise me what type of tool i need to use to remove the fuel cooler attached to the fuel filter on my 2000 tdi 115. Pretty PLEEEEAAAASSSSSEEEE:Blush2:

[devonutopia]

Well, if it's not torx or an allen key, the only driver left is a star drive. These usually come in M4, M6, M8 sizes, but I've not seen this fuel cooler before. In my fabia I just have to undo 4 fuel pipe clamps, pull them off, whip out filter, drop new one in, reattach hoses, prime fuel a couple of times to fill the filter - and off I go.

[Passatguy]

Many thanks for your suggestion devonutopia. The angle sides of this recess are not acute, like a star, but more open like an allen key angle ... and yet the allen key does not fit exactly, no matter what size is used.

I think that i will have to go cap in hand to the ******* tomorrow.
Will post result for all if i have any luck.
Thank you for your reply. :Blush:

[Passatguy]

Telephoned dealer regarding this item on top of my fuel filter requesting a tool to undo the bolt. He said that they don't sell any tools to carry out work on vw cars!!

Rang another dealer who was particularly helpful and he stated that he had not seen this setup very often. The filter is in two parts, filter itself and a top section into which several pipes go.It is secured to the main filter by a 16mm Banto bolt (Not heard of until this morning). He did not sell a removal tool but could replace the central securing bolt for about £5. He suggested i ring a specialist tool company. Don't know any so rang Halfords. They contacted their specialist tool people and said that they sell fuel filter removal kits for various cars but not this set up and could not supply a 16mm banto bolt removal tool.

The Halfords rep suggested I contact a forum to see if anyone could help !!

I find this whole thing extraordinary. Am i the only person out there with this set up. This is a bulk standard year 2000 PD 115 bhp saloon car.

Anyone know where i can get a tool to remove a 16mm banto bolt please.

[doug.howsie]

See if the center of the the screw head has a small point in the middle, that prevents the the allen or torx , bit from full fitting the head . You would then need to use a allen key or torx bit with a center hole.

I noticed that the MAF sensor uses one of these to secure it the air pipe. ( which you don't need to remove ) .

Maplins do 2 complete torx and allen key kit, with almost every type of fitting. ( know as a Tamper Proof Torx-Type ) The sell for about £20.

Hope that helps.

[Passatguy]

Thank you for your suggestion doug.howsie. missus currently has the car, but from memory, i' m certain that the inside base of this banto bolt has a flat bottom to it, no recess and no protrusion upwards.

Will ask at my nearest maplins re the tools though for future jobs... had forgotten that they sold this type of stuff.

Any additional suggestions would be most welcome.

[chrisvrscrx]

Put some pics up so we can have a look!

[Passatguy]

The missus has the car for the day but i have found a pic of the item in the Haynes manual.
1316
If this has worked ok there is an attachment file here.

The 16mm "Banto bolt ", that apparently secures the fuel cooler at the top the the body of the fuel filter beneath is indicated.

Someone out there knows what to use to get this bolt off,,, don't they ?

[kenney]

What you need is a 13mm hexagon socket

[Sam]

Banto is also known as Banjo. In this case, it's a hex-head banjo bolt.

Is your Passat an early B5?

[Passatguy]

Hi Guys,
Sorry for the delay in getting back, had a rush job in work and it has taken all of my time and some.

Many thanks to all who have assisted re this item, it has undoubtedly saved me a wedge at the ******** and has added to my knowledge of one of my trusty steeds that has never let me down. I like this car so much that three weeks ago, we pushed the boat out and bought another passat ... a 130 se estate 53 plate, which is probably the best car i have ever owned.

I have already viewed loads of threads on the forum re this model and have followed the guide to clean out the two drain holes, under the battery tray and the other side as a preventative measure. (great advice)

Incidentally to answer "mycarsavw" ,my model re the fuel filter problem above is a year 2000 pd115 saloon. You probably noticed the picture i posted stated underneath, something like " for older diesel engined cars". I found the pic in a Haynes manual guide for the later model but the pic is exactly my set up in the saloon

Will be out looking for a big hex socket next week to keep me busy. Thanks Kenny and all that contributed. Hope this helps someone else in the future.;)

[passman]

It's called a banjo bolt and usually requires a spanner to release it.

[adiek3]

hi forget halfords measure the central bolt and go to b&q i bought a household radiator key which fits pefectly ps not a bleed key , it looks like an allen key but has a groove cut in it

[Eddie]

get a bolt with a 13mm head lock to nuts together on the threaded end with locktite put the head of the bolt into the bolt on the filter head and unscrew happy days

[passing]

I puzzled the same problem for a while but in the end i managed to remove it with a tool I already had - I think that the provious post is correct but I will check when I next take the cover off.
That releases the cooler which can carefully be pulled to one side. There is then a clamp on the filter body below that which requires releasing a wedge and the filter can then be withdrawn upwards. Once I sussed the bolt it was simple. The bolt is a banjo type - drilled and allows the fuel to pass through teh filter - I doubt that you could replace it with anything but the same bolt

[Eddie]

please note the banjo bolt has an o ring which also needs replacing

[Passatguy]

hi forget halfords measure the central bolt and go to b&q i bought a household radiator key which fits pefectly ps not a bleed key , it looks like an allen key but has a groove cut in it

Adiek3, spot on mate. And the best bit was that I already had one of these in my plumbing odd and ends in the garage and had forgotten all about it.
The actual handle grip end with the groove in it is 13mm as opposed to the radiator end bit which is square anyway.
So i put the handle end into the banto bolt a Hey Presto!! it fits a treat.

:DNice one guys.

[Mike McKinstry]

I had same problem and used shaft of allen key in the end also.
Beware I refitted bolt with original o ring and filter leaked badly on restart .
I have also seen under A6 forum flat spots caused by a leaky o ring on the banjo bolt-for my next filter change I will try and get new bolt and o ring from VW.
Confusingly haynes state there is a flat washer on this bolt and if there is meant to be my 130pd did not have one when last removed and did not get one on refit--maybe thats why i get intermittent limp home!!Who knows?
Maybe someone can clear up this anomally-no not primeval!

Regards ,
Mike

[midweekbeatle]

i think you will fine it is called a ribe drive, the head bolts are the same if i remember rightly

[Buzz_B6]

i think you will fine it is called a ribe drive, the head bolts are the same if i remember rightly

Not many applications for this, but i came across them ONCE before, in a fiat bravo. the rear seats were bolted in with them, as was the rocker cover. Cost me about £18 for a ribe bit set

[andre 2000]

A couple of years after the event but I have the same problem on my Passat TDI 130.

Bought a few days ago, I serviced it yesterday and had bought a new fuel filter with every intention of fitting. Only when I took the plastic engine cover off did I see the monster allen bolt. As you say, the normally helpful Haynes manual gives no reference to the bolt size.

Have slept on it [in my bed, not on the bolt] and my thoughts are to get a 75mm long bolt with a 16mm head. Will put two nuts on and tighten them together to lock them fast. Put the fixed end in the bolt and undo with a spanner on the lower of the two nuts so as not to undo them.

This should work, I guess it depends how tight the allen bolt is - it's a bit of a beastie, so is either over engineered or tighter than an otter's pocket.

If it works I will have a tool for life. :beerchug:

[hongkongstuey]

or tighter than an otter's pocket.

i think you have your euphamisms mixed up dear man, its tighter than a gnats chuff and wetter than an otters pocket, referring to an aroused state of the fairer sex :wiggle:

[martin1810]

You use a 13mm hex bit. If you purchase a set of sump plug sockets you will get one in the set.

[Hex69]

Either way works a treat, I used the bolt + 2 locknuts plus grips and it wasn't the most laborious of jobbies....:D

[dreadnoughts]

Thanks all, M8 bolt and 2-3 nuts worked for me with a spanner also.

[scruty77]

Do not undo the bolt, just grab hold of the filter & undo as you would an oil filter. It is a spin on type filter, to make it easier to restart the vehicle, fill the new filter with clean diesel and screw back onto the housing

Cheers Scruty77