Having trouble replacing fuel filter - Diesel Forum

harvestmoon · 08-23-2005, 07:48 PM

Can anyone give a good book reference (we've spent about $40 on books with little success)? We're trying to replace the fuel filter on our E350 XLT 2002 van, but are having trouble figuring out how to get the air intake out of the way to remove the cap of the fuel filter to be able to remove the filter.

Also the handle for the water seperator (water bowl) under the fuel filter cracked off and we can't get the water out. One book says to pull it and the other says to turn it. Any ideas for fixing this? Thanks so much!

Obviously, our books suck.

JimTJr · 08-23-2005, 07:59 PM

eww.. well I have never gotten any water in my fuel separator..but you still want the handle to work,,good thing it isnt stuck open!\
I know the separator handle/valve is replaceable...there are a couple "O" rings in there that can leak too.
Those darn vans... I am sure someone with vans on here will chime in on what you have to remove/replace that fuel filter and valve...There are several difficulties different than the Super Duty trucks..and ..I dont have a van...sorry.

BUT WELCOME TO TDS! You will find all the answers you need on here,,,,even though I couldnt help with this one! Enjoy this sight,, I know I do!

Larry M · 08-23-2005, 08:29 PM

[ QUOTE ]
Can anyone give a good book reference (we've spent about $40 on books with little success)? We're trying to replace the fuel filter on our E350 XLT 2002 van, but are having trouble figuring out how to get the air intake out of the way to remove the cap of the fuel filter to be able to remove the filter.

Also the handle for the water seperator (water bowl) under the fuel filter cracked off and we can't get the water out. One book says to pull it and the other says to turn it. Any ideas for fixing this? Thanks so much!

Obviously, our books suck.

[/ QUOTE ]

Kathy,

There is a forum here called the "E-Series Vans" where all us "strange" PSD folks hang out and I've ask the mods to move this thread there. To get you help quicker you could simply make a post at the end of <font color="red"> THIS THREAD</font> that has a lot of the info you're already looking for. A lot of stuff is different in the changing of the fuel filter between the F and E-series and we can also cover that fuel drain problem since that is also different.

See you either in that thread or this one if moved.

Hang in there the Vanners are on their way [img]/ubbthreads/images/graemlins/biggrin.gif[/img]

Larry

JimTJr · 08-24-2005, 06:26 AM

Larry to the rescue!! Help that "Damsel In Distress" LOL.. Heck,, I forgot there was a thread for all you "Strange" folks!!! LOL
(Kathy ,,your not strange..ok!)
Thanks Larry,,, I thought of you soon as I read her post..figured you would chime in!

Larry M · 08-24-2005, 06:36 AM

[ QUOTE ]
Larry to the rescue!! Help that "Damsel In Distress" LOL.. Heck,, I forgot there was a thread for all you "Strange" folks!!! LOL
(Kathy ,,your not strange..ok!)
Thanks Larry,,, I thought of you soon as I read her post..figured you would chime in!

[/ QUOTE ]

ROTFLMAO, Hey I even got a PM last night queing me into a "VANNER IN DISTRESS" that prompted me to get the wheels turning. If she's actually doing the work she's a gem for sure since working on these things can be very daunting at times. Because of the forum and title of the thread where this was originally posted, I might have never read it since the F-series and E-series are so different and there are plenty of F-series folks to help out other F-series folks.

I just wonder where she's at [img]/ubbthreads/images/graemlins/shrug.gif[/img] since she hasn't posted here or in that other thread since her distess call of last night.

Larry

ddog · 08-24-2005, 05:41 PM

Kathy,
If you PM me a fax number I'll copy and fax to you the fuel filter change instructions from the 7.3 PSD diesel owner's manual supplement. They are quite good. The cap removal tool that Snap-On sells works well its about 16.00 and allows you to use a 3/8 ratchet on the factory fuel filter cap. To get to the fuel filter you need to remove the doghouse (interior engine cover), remove the turbo heat shield,remove the bolt securing the rear of theintake resonator(black plastic box),Open the hood and remove the air box assembly(4-8mm bolts hold the metal bracket that supports the plastic box, 2 in the radiator support and two in the back,loosen big oval clamp,unplug temp sensor on pass side).With the box out of the way loosen clamp that holds the resonator to the air intake tube. You can now push the resonator out of the way to gain access to the top of the cap. Moving the electrical plug above the cap and using a bungee or rope to tie back the air intake tube makes some more room.The Snap On tool makes the job easy at this point.Drain filter before removing the cap. Pull filter out. Coat oring and seal for new filter with diesel fuel. Be sure the cap seal is flat side down on the filter housing and angled side up.Push filter down and seat,install cap being careful not to displace the seal.

Fixing your drain valve and remote release will probably be more involved and will likely involve the above steps plus removing the air intake tube(tube from the filter to the turbo), disconnect the fuel lines,and drain tube and removing the filter assembly and housing from the van in order to service the valve on the back .Is the remote release broken or the valve on the back? In any regard, These are going to be factory parts. Call the folks at www.powerstrokeshop.com, they sell OEM Ford parts at wholesale prices. FYI unless you are over 100,000 miles,the broken fuel drain valve should be covered under the 5yr, 100,000 mile engine warranty.Should only cost you the $100.00 deductible. Remaining Parts and labor on Ford.Good Luck!

Derrek

Yardbrew · 08-24-2005, 07:49 PM

Not much to add to what Derrek said.

On my van, it is necessary for me to remove the bracket that holds the mass of electrical connectors which block access to the fuel filter cap.

Bungee cords are really helpful holding stuff out of the way. There is just barely enough room to gently pull up the filter and move it forward and out.

When you position that angled cap seal gasket, it pays to be careful and gentle when you lay it on the lip of the filter housing. Then continue to be careful and screw the cap back on without bumping the gasket out of the lip groove......not letting the cap touch it until it starts the final seating as you screw it down.

I have notched my cap and filter housing so I can visually see that the cap is back in place exactly where it was before I removed it. So far (knock on wood)I haven't had a leak after replacing fuel filter.

Just changed it out today (2 solid hours for me). I probably jinxed myself by bragging about no leaks.

Yardbrew

harvestmoon · 09-08-2005, 09:58 PM

Derrek, thank you SO MUCH!!!

harvestmoon · 09-08-2005, 10:02 PM

Yardbrew, thank you very much also! We have the owner's manual supplement but it didn't say to access the fuel filter from the driver's compartment. Now that makes sense.

Thanks again so much! DH is not too excited about 2 hours to do this, but we'll see.

Again, thanks so much to you all!