S60 D5 2005 paper fuel filter change - leaking

McGandalf · Jan 6th, 2018, 18:46

Hi chaps,

I just managed to botch up a fuel filter replacement of my S60 2005 D5 and would appreciate some advice. Today wasn't a good day for Volvoforums to be taken down...!

Car has a plastic diesel filter holder with a paper filter insert (not the spin-on canister found on older D5s). I removed the holder from the housing without too much difficulty - the Laser 6238 filter wrench (specific for these cars) was well worth the £20.

I removed the old fuel filter which had been on the car for 20,000 miles - a Bosch F026402005. I replaced it with a Mann PU823x, which I understand is the exact same as the Volvo genuine diesel filter.

Both filters have a top element with a mini o-ring, and the element has four indentations making an almost complete circle. I am assuming that this element pushes into the top of the fuel filter housing before you do the holder threads up.

Both filters come with a single larger o-ring which I assume is pushed onto the threads on the filter housing.

Q1 - Does the top element just push in to the fuel filter housing, or does it screw in? If it pushes in, how is it held in place? I've had a lot of difficulties getting it to stay in place.

Q2 - It's a job to get the filter cover to thread correctly back into the threads on the filter housing. Is there an easy way to do this? Are you ok to thread the cover back into the housing with the filter loose in the cover - will it just fit into place when the threads are done up?

Q3 - As Volvoforums was down - and every other Volvo knowledge repository is less than useless - I ended up calling out the RAC who managed to (they think) put the filter in the housing correctly, and do the holder threads up. However, when I started to prime the fuel system, the fuel filter housing started leaking diesel from the top. Could the o-ring not be sitting snugly? Is there a specific place for the o-ring to sit? Is leaking expected? How tight does the filter holder need to be - hand tight?

Thanks in advance - I'd rather not have to take the car to a garage to get this sorted.

S60D5-185 · Jan 6th, 2018, 19:02

The filter itself just pushes and clicks gently into place with the mini O ring holding it there until you get the outer housing cover refitted.

MAKE SURE that if there is a plastic film cover over this small nozzle on the filter (which is there to keep dirt out during storage) that you remove this before pushing filter into place.

The large O ring slides over the filter housing and into a dedicated groove . Make sure that it is not twisted.

Rub a little diesel over the large O ring and threads and you can even fill the housing with some diesel first prior to screwing it on but it isn't absolutely necessary.

The car will self prime when the ignition is switched on and a little cranking will see it fired up.

McGandalf · Jan 6th, 2018, 19:04

Thanks.

How tight does the filter holder need to be when you screw it back on the housing? Also, is any leaking to be expected (initially as it beds in)?

S60D5-185 · Jan 6th, 2018, 19:09

Quite tight but don't go overboard. You will know when its on properly.

You may feel that it is rather notchy when screwing it back on but it's simply the plastic threads being a little dry hence the rub with diesel. Make sure that it is not started cross threaded!

You will have no leaks whatsoever provided that you have assembled everything correctly , nipped it up properly and the top housing itself has not been cracked when working on it.

McGandalf · Jan 6th, 2018, 19:14

In the absence of any fresh diesel to lubricate the threads (apart from what the car dumps out of the filter housing onto my driveway), would a bit of clean engine oil on the threads be a substitute (or would this cause any harm)?

S60D5-185 · Jan 6th, 2018, 19:16

That would be fine, but just enough to lubricate the threads.

GrahamBrown1 · Jan 6th, 2018, 19:17

Do you still have the filter box? Does it say VW on it? I had this issue as the fit is poor. Euro car parts denied it was the wrong filter but it just is! I did a thread on it on this section some years ago now. I had no leakage but it just wasn’t right. If I remember correct the correct Mann filter is a PU825

McGandalf · Jan 6th, 2018, 19:19

Many thanks. I'll give it a whirl tomorrow morning in the daylight.

I am a little concerned as to why the RAC man insisted the filter was leaking from the top of the housing when I primed the engine - I'm only hoping my housing isn't broken. He probably hadn't got the cover screwed on properly, or the o-ring may have been in the wrong place/twisted.

S60D5-185 · Jan 6th, 2018, 19:19

I always use a Mann HU 719/8x from ECP. A good filter.

McGandalf · Jan 6th, 2018, 19:22

Quote:

Originally Posted by S60D5-185

I always use a Mann HU 719/8x from ECP. A good filter.

Isn't that the oil filter?

I hope it is - as I put a Mann HU 719/8x in my oil filter housing earlier this afternoon!

Jan 6th, 2018, 18:46	#1
McGandalf Member Last Online: Feb 1st, 2022 10:11 Join Date: Mar 2015 Location: Hampshire	S60 D5 2005 paper fuel filter change - leaking Hi chaps, I just managed to botch up a fuel filter replacement of my S60 2005 D5 and would appreciate some advice. Today wasn't a good day for Volvoforums to be taken down...! Car has a plastic diesel filter holder with a paper filter insert (not the spin-on canister found on older D5s). I removed the holder from the housing without too much difficulty - the Laser 6238 filter wrench (specific for these cars) was well worth the £20. I removed the old fuel filter which had been on the car for 20,000 miles - a Bosch F026402005. I replaced it with a Mann PU823x, which I understand is the exact same as the Volvo genuine diesel filter. Both filters have a top element with a mini o-ring, and the element has four indentations making an almost complete circle. I am assuming that this element pushes into the top of the fuel filter housing before you do the holder threads up. Both filters come with a single larger o-ring which I assume is pushed onto the threads on the filter housing. Q1 - Does the top element just push in to the fuel filter housing, or does it screw in? If it pushes in, how is it held in place? I've had a lot of difficulties getting it to stay in place. Q2 - It's a job to get the filter cover to thread correctly back into the threads on the filter housing. Is there an easy way to do this? Are you ok to thread the cover back into the housing with the filter loose in the cover - will it just fit into place when the threads are done up? Q3 - As Volvoforums was down - and every other Volvo knowledge repository is less than useless - I ended up calling out the RAC who managed to (they think) put the filter in the housing correctly, and do the holder threads up. However, when I started to prime the fuel system, the fuel filter housing started leaking diesel from the top. Could the o-ring not be sitting snugly? Is there a specific place for the o-ring to sit? Is leaking expected? How tight does the filter holder need to be - hand tight? Thanks in advance - I'd rather not have to take the car to a garage to get this sorted.

Jan 6th, 2018, 19:02	#2
S60D5-185 Me ? Surely Not! Last Online: Apr 25th, 2024 19:48 Join Date: Jul 2010 Location: 2007 Volvo XC90 D5 Geartronic. South of Hadrians Wall.	The filter itself just pushes and clicks gently into place with the mini O ring holding it there until you get the outer housing cover refitted. MAKE SURE that if there is a plastic film cover over this small nozzle on the filter (which is there to keep dirt out during storage) that you remove this before pushing filter into place. The large O ring slides over the filter housing and into a dedicated groove . Make sure that it is not twisted. Rub a little diesel over the large O ring and threads and you can even fill the housing with some diesel first prior to screwing it on but it isn't absolutely necessary. The car will self prime when the ignition is switched on and a little cranking will see it fired up. __________________ “Do the right thing. It will gratify some people and astonish the rest.” – Mark Twain 😊 2007 Volvo XC90 D5 SE Geartronic

Jan 6th, 2018, 19:09	#4
S60D5-185 Me ? Surely Not! Last Online: Apr 25th, 2024 19:48 Join Date: Jul 2010 Location: 2007 Volvo XC90 D5 Geartronic. South of Hadrians Wall.	Quite tight but don't go overboard. You will know when its on properly. You may feel that it is rather notchy when screwing it back on but it's simply the plastic threads being a little dry hence the rub with diesel. Make sure that it is not started cross threaded! You will have no leaks whatsoever provided that you have assembled everything correctly , nipped it up properly and the top housing itself has not been cracked when working on it. __________________ “Do the right thing. It will gratify some people and astonish the rest.” – Mark Twain 😊 2007 Volvo XC90 D5 SE Geartronic Last edited by S60D5-185; Jan 6th, 2018 at 19:15.

Jan 6th, 2018, 19:16	#6
S60D5-185 Me ? Surely Not! Last Online: Apr 25th, 2024 19:48 Join Date: Jul 2010 Location: 2007 Volvo XC90 D5 Geartronic. South of Hadrians Wall.	That would be fine, but just enough to lubricate the threads. __________________ “Do the right thing. It will gratify some people and astonish the rest.” – Mark Twain 😊 2007 Volvo XC90 D5 SE Geartronic

Jan 6th, 2018, 19:17	#7
GrahamBrown1 VOC Member Last Online: Today 14:13 Join Date: Feb 2013 Location: North Yorkshire	Do you still have the filter box? Does it say VW on it? I had this issue as the fit is poor. Euro car parts denied it was the wrong filter but it just is! I did a thread on it on this section some years ago now. I had no leakage but it just wasn’t right. If I remember correct the correct Mann filter is a PU825 __________________ Previous -03 S40, 04 V70 D5, 04 V70 D5 Sport, 05 V50, 07 S60 D5, 09 V70 D5 R design, 12 XC60 DrivE, 15 V60 D3 Current- 05 XC90 D5 Exec, 12 XC70 D4 AWD Se Lux, 14 S80 D3 Se Lux Last edited by GrahamBrown1; Jan 6th, 2018 at 19:19.

Jan 6th, 2018, 19:04	#3
McGandalf Member Last Online: Feb 1st, 2022 10:11 Join Date: Mar 2015 Location: Hampshire	Thanks. How tight does the filter holder need to be when you screw it back on the housing? Also, is any leaking to be expected (initially as it beds in)?

Jan 6th, 2018, 19:14	#5
McGandalf Member Last Online: Feb 1st, 2022 10:11 Join Date: Mar 2015 Location: Hampshire	In the absence of any fresh diesel to lubricate the threads (apart from what the car dumps out of the filter housing onto my driveway), would a bit of clean engine oil on the threads be a substitute (or would this cause any harm)?

Jan 6th, 2018, 19:19	#8
McGandalf Member Last Online: Feb 1st, 2022 10:11 Join Date: Mar 2015 Location: Hampshire	Many thanks. I'll give it a whirl tomorrow morning in the daylight. I am a little concerned as to why the RAC man insisted the filter was leaking from the top of the housing when I primed the engine - I'm only hoping my housing isn't broken. He probably hadn't got the cover screwed on properly, or the o-ring may have been in the wrong place/twisted.

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