Fossicker
Thought I'd share a recent experience with the fuel filter on my 04 D2Td5. Driving home from work on the freeway I noticed a film of fluid building up on my rear window. It was fuel that was leaking slowly from the fuel filter - the plastic threaded plug that is located at the bottom of the filter must have been knocked by something and had partly broken away. Quick call to local workshop no good as they were closing for the day and had commitments. Got the car home, leaking fuel at a rate of approx 1 litre every 5 minutes. At home I tried to wrap some putty around the split area but the plug gave way entirely, leaving the hollow threaded body of the plug in the filter body. Of course you start the engine and try and drive that anywhere and the diesel spews out like a kitchen tap on full. Ain't driving anywhere like that. Solution? Remove the remaining thread from the filter and replace with a 10mm threaded bolt - filled the hole perfectly. Now I'm not a mechanic or car design expert but surely you are asking for trouble using a plastic plug in the fuel delivery system of a 4WD, exposed and facing down towards the ground. I wonder if anyone else has heard of this happening? Lucky I had been on the freeway with enough speed for the fuel to be drawn up on to the window - imagine if I had been meandering on a track somewhere in the high country losing fuel and not knowing it...
Always carried a bolt in the ashtray for the fuel filter in my D2 and always removed the plastic plug and put a bolt in when I went on any offroad trips.
There are some threads on here where people have made guards for the filter, from memory 1 was using some PVC pipe that was longer than the filter to protect the plastic bung.
Well done finding a bolt that fitted.
Cheers Ean
Swaggie
Yep,also kept the bolt in the glovebox,after SWMBO came back from the shops one day & informed me the disco smelt of diesel.
On inspection there was a pool of diesel under the rear right hand side of the vehicle,parked in the carport, about one meter in diameter.
I recon the plastic part of the filter deteriorates with the heat,as the filter runs quite hot.
YarnMaster
Good thinking. Bolt size?Originally Posted by scarry
D4 MY16 TDV6 - Cambo towing magic, Traxide Batteries, X Lifter, GAP ID Tool, Snorkel, Mitch Hitch, Clearview Mirrors, F&R Dashcams, CB
RRC MY95 LSE Vogue Softdash "Bessie" with MY99 TD5 and 4HP24 transplants
SADLY SOLD MY04 D2a TD5 auto and MY10 D4 2.7 both with lots of goodies
Swaggie
M10 x not longer than 25mm. You'll probably have to shorten one.
Cheers
Slunnie
~ Discovery II Td5 ~ Discovery 3dr V8 ~ Series IIa 6cyl ute ~ Series II V8 ute ~
Master
SupporterI had this problem a few years ago.
I've actually made a proper drain plug by drilling the 10mm stainless bolt to for about 10mm and then drilling a cross hole.
Reuse the original rubber seal from the plastic plug.
TD5 Fuel Filter Drain Plug Failure
I just have to remember to get the stealers to recover my bolt from the garbage can whenever the filter is replaced.
Wizard
Or you could carry a few spare plugs as I do. I renew them every filter change and keep the old ones.
Regards
Robbo
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