Hi All,
I'd been putting off changing the diesel fuel filter in my PD for a few months, last had it done a couple of years back and paid a mechanic to do - ($150 which included the filter but this was a 'mates rate' he said it was a crappy job to do).
Thankfully there's lot of YT tuts on this - and after watching a bunch of them I gave it a crack.
I didn't want to remove any more of the engine than required - and got away with taking out only the battery and the ECM.
TAKE PHOTOS or video first so you know what goes where. A good light is handy as is right at the back of the engine bay.
Oddly the trickiest bit by far was figuring out how to remove one of the sensor clips that goes directly into the filter housing. No real special tools needed, basic socket set, extension bar (to get the battery's clamp off). A bench vice is handy to hold the old filter (& new one) as you remove the top section. Also a bit of fresh diesel to fill the new filter back up.
Undo all the clips and sensors, do the same with undoing the fuel lines - be gentle with these & try not to get grit or dust in them (I gave a quick clean up around the general area BEFORE starting the job).
The bracket that the fuel filter is in has 10mm screws holding it onto the car up high and down low, take your time to remove these - careful not to drop into the engine - can be tight to get at.
I didn't have to remove the air manifold, air filter etc - but you can if it assists you.
Remove the fuel filter bracket, have a container ready as it will be full of diesel. Empty this out, wipe down the assembly and remove the old filter. Unscrew the water sensor at the bottom - set aside including the rubber seal as most kits do NOT come with another one of these.
Unscrew the filter from the housing. Use a vice or multigrips to remove the top section of the housing from the filter. Pour out old diesel, dispose of properly (not down the drain!).
Take new filter, apply some clean oil to it's top seal. Screw water sensor into the base of it, doesn't need to be overly tight. Screw the new filter into the top section of the assembly AFTER you have filled it with clean diesel fuel. Hand tight only.
Screw the entire new filter back into the bracket housing. Do not tip it too much or the fuel will come out. Put back into car, finger tighten the screws that hold it on. Reattach the fuel hoses, making sure you wipe down the connections on the filter bracket with a clean rag BEFOREHAND.
Reclip the sensors back on. Tighten the screws and place the ECM back in and tighten, and then the battery, reattach the battery.
Then you need to purge the air from the fuel lines, this is done by cycling the ignition a half dozen or so times - by pressing the ignition button but NOT actually starting the car. Then start the car & check for any leaks.
All the sensors only go on one way & are unique to each other - so aside from getting the fuel hoses clicked back on very little to 'mess up'.
Is not that hard a job, don't be scared off it. Took me about an hour total, easily doable in 30mins.
