Description
496 Fuel Filter Assembly — Complete Fuel Filtration, Right Out of the Box
The iFJF 496 fuel filter assembly is a ready-to-install fuel polishing station for your tank, transfer pump, or dispensing system. It combines a 30-micron filter element, clear hyaline water-separation bowl, and zinc-plated 1" NPT top cap into one complete unit. Designed for gasoline, diesel, biodiesel (up to B20), and fuel oil — it handles up to 25 gallons per minute at 150 PSI. If your current setup has a rusty cap, a cracked bowl, or a clogged filter you can't see through, this is the drop-in upgrade.
Key Features
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Complete Assembly — No Parts to Hunt: Comes fully assembled with the zinc 1" NPT top cap, 30-micron filter element, hyaline see-through bowl, drain valve, and gaskets — everything you need in one box. Unscrew the old unit, thread this one on, and you're filtering.
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30-Micron Filtration: Traps rust, sand, dirt, pipe scale, and other particulate down to 30 microns — protecting injectors, carburetors, and fuel pumps from abrasive wear. Ideal as a primary/bulk filter before finer secondary filtration.
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Water Separation: The hyaline bowl acts as a gravity water separator. Water (heavier than fuel) settles to the bottom while clean fuel rises to the outlet. The clear bowl lets you see exactly when it's time to drain.
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High Flow — 25 GPM Max: With a 1" NPT inlet/outlet and low-restriction element, this assembly supports flow rates up to 25 gallons per minute. Perfect for fuel transfer pumps, tank filling stations, and high-volume dispensing.
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Zinc-Plated 1" NPT Cap: The top cap is cast and machined with 1" NPT female threads. Rust-resistant zinc plating prevents the seized-thread nightmare common with bare steel caps. Large wrench flats for easy installation.
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Multi-Fuel Compatible: Rated for unleaded gasoline, diesel #1/#2, biodiesel up to B20, fuel oil, and related additives. One assembly covers everything on the farm or in the shop.
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150 PSI Working Pressure: Built with a substantial safety margin for typical fuel system pressures (most transfer pumps run 30-60 PSI). The thick-wall hyaline bowl and reinforced cap can handle pressure spikes without failure.
What's Included
| Component |
Material |
Spec |
| Top Cap |
Zinc-Plated Steel |
1" NPT Female Inlet/Outlet |
| Filter Element |
Cellulose/Synthetic Blend |
30 Micron, 496-5 Compatible |
| Filter Bowl |
Hyaline Polymer |
See-Through, Alcohol-Resistant, Drain Valve |
| Gaskets |
Nitrile Rubber |
Bowl-to-Cap Seal (Pre-Installed) |
| Drain Valve |
Brass/Bronze |
Bottom-Mounted, Finger-Operated |
Specifications
| Specification |
Value |
| Part Number |
496 / 496-ZH |
| Filter Rating |
30 Micron (Nominal) |
| Max Flow Rate |
25 GPM (95 LPM) |
| Max Working Pressure |
150 PSI |
| Inlet / Outlet |
1" NPT Female |
| Bowl Material |
Hyaline Polymer (See-Through) |
| Cap Material |
Zinc-Plated Cast Steel |
| Fuel Types |
Gasoline, Diesel, Biodiesel (B20), Fuel Oil |
| Replacement Element |
496-5 Filter Element |
Typical Applications
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Fuel Transfer Tanks: Mount inline between your transfer tank and pump to catch tank-bottom debris before it reaches your equipment.
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Farm Fueling Stations: Filter bulk diesel or gasoline before it goes into tractors, combines, and trucks. The 25 GPM flow rate won't slow down your fill-ups.
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Above-Ground Storage Tanks: Install on the discharge side to polish fuel before dispensing. The clear bowl gives you instant visual confirmation of fuel quality.
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Generator Fuel Systems: Protect standby generator injectors from tank condensation and rust. The water separator is especially valuable for diesel generators that sit for months between runs.
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Marine Fuel Systems: Filter tank fuel before it hits your engine's primary filter. Water separation is critical in marine environments where condensation is constant.
Maintenance & Replacement
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Filter Element: Replace every 500-1,000 gallons of fuel throughput, or when you notice reduced flow. Use the 496-5 replacement element.
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Bowl Inspection: Check the hyaline bowl monthly for clouding, cracking, or drain valve leakage. Replace with the 495-4 replacement bowl if needed.
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Water Drain: Drain accumulated water weekly (or daily in high-humidity environments). Simply crack the bottom valve until clean fuel appears.
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Bowl Wrench: Use the 491 bowl wrench for damage-free bowl removal — never use a strap wrench or channel locks.
Frequently Asked Questions
Q: What does "30 micron" mean and is it enough for my diesel engine?
A: 30 micron means the filter catches particles 30 microns (0.03mm) and larger. This is the standard rating for primary/bulk fuel filtration — it stops rust, sand, and pipe scale. For final engine protection, your vehicle's onboard fuel filter (typically 2-10 micron) handles the fine stuff. The 496 assembly is designed as the first line of defense.
Q: Will this work with a standard fuel transfer pump?
A: Yes — it supports up to 25 GPM and 150 PSI. Most transfer pumps run at 10-20 GPM and 30-60 PSI, well within the 496's capability. The 1" NPT ports fit standard fuel plumbing.
Q: Can I mount this in any orientation?
A: The bowl must be oriented downward (vertical) for proper water separation. Water sinks to the bottom of the bowl — if the assembly is mounted sideways, water won't collect in the drain zone.
Q: How do I know when to change the filter element?
A: Three signs: (1) Reduced flow rate at the nozzle — the most obvious indicator. (2) The element looks dark and loaded when viewed through the clear bowl. (3) You've processed 500-1,000 gallons since the last change. Keep a spare 496-5 element on hand.
Q: Is the 1" NPT cap compatible with my existing plumbing?
A: 1" NPT is the standard size for fuel transfer and dispensing systems. Your existing fittings, nipples, or hoses should thread right in. Use PTFE thread sealant (not tape) on NPT threads for a fuel-tight seal.
