240 General: Replacing Fuel filter

[Paul240480]

Replaced my fuel filter today & took a few pics along the way. I hope you find them of use.


Old (Bosch) filter in situ & new Mann filter ready to go. The bosch one was there on purchased in 2003 :shock: Over 50k miles with me, who knows how many before :?


You need to release pressure in the fuel system. Pull fuse #6, then run engine till it stops. Finally remove fuel filler cap. If the fuel pump fuse is showing signs of overheating, now is a good time to replace it!


Disconnect -ve terminal of battery!


Disconnect output side of fuel filter (can do input first, this is just the routine I used). Note using an adjustable spanner on the filter to allow the 17mm on the nut to be used with a bit of force.


Then disconnect the 15mm connector on the brass elbow joint on the input side. This is a bit fiddly due to the bonnet hinges & spring being 'in the way'.


Next undo the 10mm nut on the fuel filter holding bracket. This has a captive nut by the way.

You can now remove the filter, although you may need to spin it free from the output pipes thread. Some fuel will no doubt spill out.


Next you need to remove the brass elbow joint from the input end of the filter. I did this on my bench.


New filter with the elbow screwed in ready to be mounted.


New filter in place.

Refit (new) fuse #6

Re-connect battery

Start engine, which may take longer than normal to allow fuel to get through new filter & thoroughly check for signs of leaks!
Hopefully all will be well
If I've missed anything, please feel free to add info'

[Mike_Brace]

Very useful "how to" Paul - it's something I haven't done for over ten years thanks to running lpg.

It is worth making sure you have a good quality fuse (genuine Volvo ones are not expensive) as some are a soft plastic and with slightly corroded contacts will rapidly get hot and the plastic softens giving a poor contact.

Mike

[Clifford Pope]

I must confess I didn't do any of that depressurising stuff. I just loosened the banjo bolt a little and wrapped a rag round it to contain the small spillage.

[wooble]

good writeup, for everyone else out there, always use new copper washers on the fuel filter when available, if your new filter doesn't come with them you can re-anneal the old ones be heating them until red with a butane torch (or your cooker's gas hob!) than dunking them into water, brings them up all shiny, malleable and new again! Also, always check very carefully for leaks with the engine running, the slightest leak could let fuel drip or spray onto the hot manifold, with obvious consequences!

[nickbw898]

Great write up. My experience was that these fuel unions can be very tight, having probably never been undone since manufacture! Has anyone else got an exceptionally noisy fuel pump and if so have you changed it? I am not sure if it is the external pump fitted under the rear on the near side, or if like more recent models, there is a secondary pump but mine is so intrusive the noise is distracting. There is always the chance it will fail outright ever present in one's conscious while driving!

[chesters6]

i guess its one of those posh injection engines? mine just has a tiny inline filter unless its been "adjusted"

[Paul240480]

Originally Posted by chesters6

i guess its one of those posh injection engines? mine just has a tiny inline filter unless its been "adjusted"

Yes tis Chesters B200E, sorry! LOL