Installation for EZ Bypass Filter Kit for BEW Engines Only

This page includes detailed instructions on how to install the EZ Bypass Filter Kit on the 2004-2006 Golf and New Beetle TDI and also on the 2004 through early 2005 Jetta TDI with the BEW engine. To install the EZ Bypass Filter Kit you will need all of the items listed below, including the tools.

Dieselgeek Bypass Filter Kit parts list:

Tools needed:

Supplies needed:

 

Installing Oil Feed Line and Bypass Filter “Double Clamp”

  1. Always work on a cold engine.  Remove the engine cover by first removing the oil dip stick and then pulling the cover off of its three quick release mounts. Replace the oil dipstick once the engine cover is off.  Next, take a quick look at Step 10 before proceeding.

  2. All 2004-2006 Golf, Jetta and New Beetle TDI’s with the PD “BEW” code engine use oil filter housings that have just one oil pressure switch on the passenger side of the oil filter housing. This is the upper port as shown in the picture below.


    You will install
    feed line at oil
    pressure switch at top.


  3. Unplug oil pressure sender on lower left side of oil filter housing. There is a catch that must be depressed away from the sender in order to remove this plug. (Sometimes this step is easier after you loosen the sender with your 15/16" or 24mm wrench as it rotates the plug into a position where you can see the release catch.)


    Unclip plug from the Sender

    Loosen the Sender


  4. Unclip the oil pressure sender’s wire loom from the plastic keeper that holds it.  This will give you enough slack to plug the sender wire back into the sender in its new position. Be sure to place the wire back in the plastic keeper after the oil feed line is installed.


    Unclip Oil Pressure
    Sender wire


  5. Place rags below the oil pressure sender to catch the motor oil that will run out after the sender is removed.  Next, loosen the sender with a 24mm or 15/16" wrench.  Finally, remove sender and clean it with brake cleaner spray and an old tooth brush and/or a shop rag if it is dirty.


    Loosen the Sender

    Remove Sender


  6. Thread the clean oil pressure sender into female side of the kit’s "Piggyback" banjo bolt.  Tighten to 18 ft-lbs. or "pretty snug". Tighten sender using either a vise or counter-tighten the sender into the banjo fitting with a 9/16" box end wrench and 15/16" (or 24mm) box end wrench as shown below.


    "Piggyback" Banjo bolt

    Thread Pressure Sender In

    Either tighten sender in a Vice

    Or Counter Tighten by hand


  7. Place one of the aluminum sealing washers onto the male end of the "Piggyback" banjo bolt.  Next, slide banjo bolt through the hollow banjo fitting of the supplied braided steel oil supply hose.


    Aluminum Sealing Washers

    Male end of the
    "Piggyback" Banjo bolt

    Slide banjo bolt through hollow
    oil line fitting


  8. Place the second aluminum sealing washer onto the male end of the banjo bolt and hand thread the banjo bolt into the oil sender hole on the engine’s oil filter housing.  Leave the oil line slightly loose as you will be "clocking" it in Step 14 below.  Your installed oil line will look like this and this.


    Aluminum sealing washer
    with other sealing washer
    on the male end

    Your installed oil
    feed line will
    look like this

    Your installed oil
    feed line will
    look like this


  9. Next, plug the oil pressure sender wire back into the oil pressure sender once the sender and banjo bolt has been threaded in and is almost tight. Pull gently on the plug (not the wire) to make sure the catch of the plug is fully engaged.  This plug and wire supplies a signal for the low oil pressure warning light and alarm in the instrument cluster. Also, make sure that the oil sender wire is put back into the plastic keeper you removed it from in Step 4.

  10. If you have not already done so, remove the Amsoil bypass filter from its box.  Fill the bypass filter through the center hole with new motor oil. The filter will hold nearly a quart of oil if you start filling 30 minutes before you need to lower the filter and cap assembly into the engine bay. (Don’t worry if you cannot fill the filter completely as the engine will finish the job for you when you start the engine.)  Next, thread the billet aluminum filter cap onto the oil filled bypass filter.  Make sure it is very snug and make sure to keep the filter upright after filling!


    Amsoil bypass filter


  11. Lower the “Double Clamp” aluminum filter holder onto the oil filter housing.  The “Double Clamp” should sit ¾” from the top of the oil filter housing’s aluminum casting (shown with filter already installed). With a 6mm Allen wrench, tighten the Allen clamping screw holding the “Double Clamp” to the stock filter housing to 10 ft-lbs. or “pretty tight” and be aware that over tightening this Allen screw can damage the filter housing.  Note that there are several degrees of adjustability (clockwise or counter-clockwise) in where you tighten the “Double Clamp”.  You may rotate the “Double Clamp” to position the bypass filter as far from other objects as possible.  Please note that the bottom of the Amsoil bypass filter will touch one of the coolant hoses running to the oil cooler below but this is o.k.  (On the New Beetle the filter will press down on both the oil cooler hose and power steering hose).  Also, on the Golf and Jetta the upper radiator hose will be very close to the double clamp as shown in this picture.


    ¾” from the top

    Allen clamping screw

    Radiator hose very
    close to double clamp


    On the Golf or Jetta only, if the protruding “ears” of the hose clamp touches the double clamp you can rotate the hose clamp ears to face upwards with hose clamp pliers or a pair of channel lock pliers so that they do not touch.  
    Also on the Golf or Jetta only you may want to loosen the upper radiator hose’s spring type hose clamp at the coolant flange and rotate the upper hose as shown in this picture to gain more clearance between the double clamp and upper hose.


    "ears"

    Ears face up

    Channel locks

    Rotate the upper hose


  12. Lower the Amsoil bypass filter and cap into the double clamp.  Tighten the Allen clamping screw for the bypass filter and then make sure the bypass filter cap is nice and tight with your ½” ratchet and extension bar.  Next, loosen the Allen clamping screw for the bypass filter and rotate and/or raise or lower the filter to position the filter cap’s fixed 90 degree elbow fitting to point exactly toward the oil feed line and can easily thread onto it.  Hand thread the oil feed line to the cap’s fixed 90 degree fitting.  Finally, re tighten the bypass filter’s Allen clamping screw at a height where the oil feed line makes a nice smooth bend. Be careful not to over tighten the clamping screw for the filter.


    Amsoil bypass filter

    ½” ratchet and extension bar

    Allen clamping screw
    for the bypass filter

    Hand thread


  13. Tighten the braided stainless steel oil line to the filter base’s conical 90 degree elbow by using a 14mm wrench.  Sometimes it helps to spray the oil feed line’s fitting nut with WD-40 to allow it to be tightened without twisting the braided oil feed line.  "Pretty snug" is the torque spec on the fitting nut. Do not over tighten this fitting as it wears out the conical sealing surfaces!


    90 Degree Elbow

    Spray Fitting Nut


  14. Finish tightening the banjo bolt at the lower end of the braided steel hose so that is "pretty snug". (18 ft-lbs is the official specification though getting a torque wrench on this is difficult to achieve in such a tight space.)  Also, make sure the oil line makes a nice smooth curve as it rises to the top of the oil filter housing.  Do not over tighten the piggyback banjo bolt as it is threaded into aluminum.  Tip: Hold onto the oil line as you tighten the banjo bolt so that it does not rotate.


    Tighten Banjo Bolt


  15. On the New Beetle only the upper radiator hose touches the edge of the double clamp as shown here.  The upper radiator hose must be trimmed by ½” to gain the necessary clearance for this hose. To do this, the hose must be removed from the plastic flange as shown here.  Having the front of the car up on ramps or jack stands will be helpful in keeping coolant loss to a minimum while removing the coolant line from the radiator flange. Also, draining a small amount (1/2 liter or 1 pint) of coolant from the radiator through the radiator drain valve on the bottom driver’s side of the radiator will reduce spillage as well.  Use a brand new razor blade to make a clean cut all of the way around the hose. You will be left with a ½” wide ring of rubber hose.  Reinstall the modified upper radiator hose onto plastic coolant flange after you make the cut. Clamp the hose using the stock spring clamp.  Top off the coolant reservoir with a 50:50 mixture of coolant and water after the engine has been run.  More pictures of this procedure will be posted here by September 1st, 2007.


    Double clamp

    Plastic flange


 

Installing the Kynar Clean Oil Return Line

  1. Installing the return tubing: We have preinstalled the correct length of Kynar return tubing into the supplied oil fill cap to make a nice, smooth flowing bend on this line when installed between the valve cover and the bypass oil filter cap. To install, remove your stock oil fill cap and replace it with the oil cap we have provided with the bypass kit.  If installed correctly, the oil line will curve gently toward the bypass filter cap.  Connecting the return tubing to the filter cap requires you to simply insert the line into the fitting until it positively stops (.600") or just a little bit more than a half of an inch.


    Smooth flowing bend

    Insert the line


  2. If you need to disconnect the line: push the outer chrome ring on the push-to-connect fitting toward the fitting while gently pulling on the line and the line will come out of the fitting.  Try not to cycle the Kynar tubing in and out of the fittings too many times as seeps can develop at fittings that have been removed/reinstalled too many times.


    To release line:
    Push Outer Chrome Ring
    toward fitting and pull gently on line


  3. The return oil tubing will sit directly above a grayish white spring hose clip for a fuel line.  To gain more clearance for the oil line you must rotate the spring clip downward with hose clamp pliers or a pair of channel lock pliers. The correct orientation is shown in this picture.


    Channel lock

    Correct orientation


  4. Check all oil line unions to make sure they are tight.  Next, have someone else start your engine while you watch for leaks at the bypass filter line unions. You should see the opaque Kynar line fill with oil within 10-20 seconds of start up and no leaks should be present.  If there are seeps or leaks, turn engine off and tighten the union which is leaking by a small amount.  Make sure to clean the union off with brake cleaner and test again.  If there are no leaks, take a very short test drive and check for leaks again.  Also, when you return from your test drive stop the engine and give the oil at least five minutes to drain back to the oil pan and recheck your engine oil level.  Make sure to recheck the bypass assembly for seeps several times in the next few days.  Tighten fittings in small steps if there are seeps to prevent over-tightening. Please do not drive the car with a leak present.

  5. Do not replace the engine cover until you have checked for seeps or leaks. Leaving the engine cover off for a week or two is the best way to do this.

  6. When you are ready to reinstall your engine cover you will need to make a small clearance cut in the plastic ring where the Kynar oil line touches it.  Make the clearance hole at least ¼” wider than it needs to be to ensure that the return line does not rub on the engine cover.  Also, you may elect to install the decorative oil cap cover we provided with the kit. It simply slips over the modified oil cap. The slit in the side of the cap fits around the Kynar oil line.


    Kynar oil line

    Decorative oil cap cover


 

Adding oil to the engine and Servicing the Bypass Filter

Have any questions? Email me directly at with any questions, suggestions, comments, or random superlatives...