Description
496-5 Replacement Filter Element — Keep Your Fuel System Flowing
The iFJF 496-5 is the exact replacement filter element for the 496 and 496-3/4 fuel filter assemblies. When your filter loads up with rust, sand, and tank debris — swap in a fresh 496-5 element and you're back to full flow. The 30-micron cellulose/synthetic blend media provides high dirt-holding capacity without excessive restriction, and the anti-collapse reinforced center plate prevents the element from crushing under pressure — a common failure point in cheap replacement filters.
Key Features
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Direct Replacement — No Mods: Exact fit for the 496 and 496-3/4 fuel filter assemblies. Drops into the housing in seconds — unscrew the bowl, pull the old element, push in the new one, reinstall the bowl.
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30 Micron Filtration: Captures rust particles, sand, dirt, pipe scale, and tank debris down to 30 microns. Protects downstream injectors, carburetors, and fuel pumps from abrasive wear.
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Anti-Collapse Reinforced Plate: A common failure with cheap filter elements is the center tube collapsing under high vacuum when the filter loads up — cutting off fuel flow entirely. Our 496-5 features a reinforced anti-collapse center plate rated to withstand full 150 PSI differential pressure without deforming.
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High Dirt-Holding Capacity: The pleated cellulose/synthetic blend media provides a large surface area for dirt loading. You get longer service intervals between element changes compared to economy filters with fewer pleats.
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Multi-Fuel Compatible: Rated for unleaded gasoline, diesel #1/#2, biodiesel blends up to B20, and fuel oil. One element type covers all your fuel filtering needs.
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Protective Sheet Included: Each element ships with a protective sheet to keep the media clean during storage. When you stock spares on the shelf, they stay ready to install — not covered in shop dust.
Compatibility — Fits These Assemblies
| Assembly |
Part Number |
Compatible |
| 496 Fuel Filter Assembly (1" NPT) |
496-ZH |
✅ Direct Fit |
| 496-3/4 Fuel Filter Assembly (3/4" NPT) |
— |
✅ Direct Fit |
| 497 Fuel Filter Assembly |
— |
✅ Direct Fit |
| 497-3/4 Fuel Filter Assembly |
— |
✅ Direct Fit |
Specifications
| Specification |
Value |
| Part Number |
496-5 / 496-LX |
| Filtration Rating |
30 Micron (Nominal) |
| Filter Media |
Cellulose/Synthetic Blend, Pleated |
| Center Tube |
Reinforced Anti-Collapse Plate |
| Max Differential Pressure |
150 PSI |
| Outside Diameter |
~3.15" (80mm) |
| Height |
~4.7" (120mm) |
| Center Hole |
~1.1" (28mm) |
| Fuel Compatibility |
Gasoline, Diesel, Biodiesel B20, Fuel Oil |
| Recommended Change Interval |
Every 500-1,000 gallons or when flow decreases |
When to Replace Your Filter Element
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Reduced Flow Rate: If your transfer pump is taking longer to fill the same tank, the element is loading up. Don't wait until flow stops — swap it at the first sign of slowdown.
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Visible Loading: If you can see the element through the clear hyaline bowl and it looks dark brown or black (instead of white/light tan), it's time.
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500-1,000 Gallon Interval: Even if the element looks clean, change it on a schedule. Rust and fine silt invisible to the naked eye build up in the media and gradually increase restriction.
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After Water Contamination: If your bowl ever fills with water (from tank condensation), replace the element. Water-saturated filter media loses efficiency and can promote bacterial growth.
Installation — 60 Seconds
- Shut off fuel flow to the filter assembly.
- Use the 491 bowl wrench to unscrew the hyaline bowl.
- Pull the old element straight down off the center post.
- Remove the protective sheet from the new 496-5 element.
- Slide the new element onto the center post until it seats against the cap.
- Reinstall the bowl — hand-tighten, then 1/8-1/4 turn with the wrench.
- Turn fuel flow back on and check for leaks.
Related Products
Frequently Asked Questions
Q: Does this element fit my 496 fuel filter assembly?
A: Yes — the 496-5 is the exact replacement element for the 496 (1" NPT) and 496-3/4 (3/4" NPT) assemblies. Also fits 497 and 497-3/4 assemblies.
Q: How often should I replace the filter element?
A: Every 500-1,000 gallons of fuel throughput, or sooner if you notice reduced flow rate. For a typical farm fueling station processing 200-300 gallons per month, this means changing the element 2-4 times per year. Keep a spare on hand.
Q: What's the difference between this 496-5 element and a generic 30-micron filter?
A: The 496-5 is purpose-built for the 496/497 assemblies. It has the correct OD, ID, height, and center hole diameter for a drop-in fit. Generic filters may be "close" in size but won't seal properly — leading to unfiltered fuel bypassing the element entirely. The reinforced anti-collapse plate is also a feature most generics skip.
Q: Can I clean and reuse this filter element?
A: No. The 496-5 is a disposable filter element. Attempting to clean it (blowing compressed air through, rinsing with solvent, etc.) damages the filter media and reduces filtration efficiency. Always replace with a fresh element.
Q: What's the protective sheet for?
A: It keeps dust, dirt, and shop debris off the filter media during storage. Remove the sheet before installation — it's not meant to stay on the element in service.
