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Discussion Starter #1
I'm looking to change the fuel filter on my 1.6 HDi 90bhp 207sw. I have a Haynes manual which in the generic part of the manual (probably in all manuals) says you need to plug the fuel lines after disconnecting them. However, in the section that details changing the filter, it just tells you to disconnect the fuel lines from the filter and have plenty of rags handy but says nothing about plugging or clamping them.

The fuel lines (I think) are quick disconnect type with a little white button on them. Do I need to clamp or plug the lines after disconnecting them or not? I've read that clamping can damage the hoses but I cannot find suitable plugs online.

For clamps, I've found these. I made something like this once back when I was in college, although it didn't look as nice as these. :lol:
Sealey Hose Pinch Tools 2pc : Tooled-Up.com

As you can guess this is the first time I've done this so any other advice is welcome. :D
 

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Discussion Starter #4
Filter is branded Blue Print, came from local motor factors. I'll check it again as it may have some plugs fitted to it... never thought of that!

loot, how much fuel did you lose?
 

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From memory i took the filter off and replaced it so whatever was in it i guess, its a plastic unit so i don't think you can fill it up like a traditional one but i had no problems starting the car up, it was a Peugeot filter.
I can't recall if the car has a manual primer sorry, but as i said, at the time if i had issues i would remember so I'd say it was straight forward.
 

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Yes you do need to plug the hoses, 2 golf tees are best for the job,

most important to leave the car stood over night to de-pressurise,

Remove the lines and plug 1 by 1?

Replace with new filter, fill new filter with diesel 1st,

You want to keep the amount of air in the system to a minimum,

Make sure u wash any diesel off of the fuel lines once finished,
 

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Discussion Starter #8
My filter does have plugs with it. They are both different and already on the filter so will just have see if they fit when I get round to do it. I don't have any golf tees, or anything else similar unfortunately.

The car has a hand pump primer fitted so not worried about that.

Thanks for all the help so far. I'll update how I get on when I get round to it. :D
 

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Discussion Starter #9 (Edited)
Ok, I've finally got round to changing the filter. No problem removing and refitting but now I'm really stuck.

The car is fitted with a hand priming pump and the Haynes manual says it only takes approximately 2 minutes to prime the system. I've been out for hours today and the pump is not showing any signs of resistance like the manual says. Used the pump for a good 20 minutes before attempting to start. First time I started the car it started normally, idled for a few seconds then died. Car would not restart.

I then pumped the hand pump again for probably an hour's worth before fuel actually went through it (resistance not changed). Have checked all the connections and all seems fine. Car eventually started but only idled for about a second then died again. Car would not restart. My hands are now too sore to carry on.

Is this priming pump just an absolute joke or is something wrong here? I live out in the sticks and car is dead so really need to get this sorted asap!
 

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It should be a 1 way valve so every pump fills the pipes with fuel, it sounds like it isn't locking, but now you have run the pump dry it'll be a bit harder now, you have plenty of fuel in the tank i take it?
I would be looking at getting suction on the outlet of the primer if it was me, I'd consider pressurising the tank but i won't suggest that really.
Does the primer seem to be sucking i.e 1 way?
I'd probably take it off and check it isn't stuck open.
Other alternative is get a bottle with a very small spout full of diesel and fill the filter up full.
:rolleyes:
 

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Discussion Starter #11
Tank is over half full, 400 odd miles. Can't feel anything when pumping. I did a few times before I tried the second last restart that I did but after that have felt nothing through the pump. There is definitely fuel in the filter as I disassembled everything again and could here fuel sloshing around in it. I suppose I could look at filling filter up manually with bottle and spout. I wouldn't know how to check the valve in the pump itself.
 

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Discussion Starter #12
Having spent another good while pumping the primer and not getting anywhere I tried something else. I opened the old filter up at the top to discover a dipstick, which also let out remaining fuel from the very bottom hose connection (unknown as to what purpose this has). The hose that connects to this is thin, yellow, flexible and translucent. The only thing that holds it in place on the filter is friction as the hose is smaller than the pipe it connects to. So, I undid the dipstick on the new filter and heard fluid movement. When this stopped I started pumping the primer and could here fuel moving again. Success, I thought.

After a few minutes pumping I checked the dipstick and it didn't seem like anything was happening. I looked under the car to find a fresh patch of diesel... All the connections I've tampered with are on correctly, no fluid is leaking from the filter.

What I think has happened is when I've took the old filter off I've pulled that yellow hose off of whatever it is connected to at the other end. Hence, primer pumping air and now fuel leak.

Does anyone know where this hose connects to and how hard it is to get to? It disappears behind the engine somewhere. If I can get to it from the top of the engine bay I may be able to do it myself, if not then its £50 recovery charge + garage bill unfortunately. :(

It looks like removal of wiper blades, trim, air filter housing and pipes will be required to get access from the top, assuming its possible to get at from the top. If access is required from below then I'm really stuck this time and its a garage only job.
 
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Did you fit the fuel heater to the new filter? You have to remove it off the old filter. There are two o-rings on it, make sure they are fitted. There should be no need to block the pipes when changing a fuel filter. I never do it. Works out every time.

Sent from my GT-S5690
 

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Discussion Starter #14
Didn't need to clamp or block pipes up. Any residue pressure on the low pressure side of the system must have gone when I got round to doing everything. Yes I put the heater on to the new filter, otherwise one of fuel lines would not have connected to the filter. I'm pretty sure everything I deliberately touched is refitted correctly.
 
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Then it should start. Get it on a peugeot diagnostic and check the cranking fuel pressure.

Sent from my GT-S5690
 

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Discussion Starter #16
After a few minutes pumping I checked the dipstick and it didn't seem like anything was happening. I looked under the car to find a fresh patch of diesel... All the connections I've tampered with are on correctly, no fluid is leaking from the filter.

What I think has happened is when I've took the old filter off I've pulled that yellow hose off of whatever it is connected to at the other end. Hence, primer pumping air and now fuel leak.
Sorry, I thought I'd made it clear. Fuel leaks from car when operating the primer pump. The end of the hose most likely responsible for the leak is not accessible and I do not know how to access it. At a guess it would require the removal of previously mentioned parts but I'd rather know for sure if I'm on the right track or not before I start dismantling the car again... If its beyond my ability then I'll just have the garage do it but ideally would like to sort it myself.
 

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Discussion Starter #17
Spoke to my mechanic today, he said the hose I was concerned about is actually a water drain hose and is not a leak. He also suggested the new filter may be a bad one. Have put the old filter back on and attempted to prime the system. Wasn't getting anywhere so I disconnected the top fuel line from the filter and operated the pump. For a while, the pump worked and sent fuel from the tank (confirmed by the vacuum disappearing when opening the filler cap and fluid noise from tank).

After a while I reconnected the top fuel line on the filter and carried on. Pump continued to pump fuel from the tank for a while but then slowly stopped. Resistance didn't change on the primer pump however. Sceptical, I rebuilt everything and attempted to start the engine. Engine did not start.

I'm beginning to think there's an air lock somewhere and that the normal primer pump, for whatever reason, can't shift it. Going to speak to a more local mechanic tomorrow so hopefully it won't be a big job and require a tow. If he can't sort it (he works mainly on quads and tractors) then it'll be a tow to my car mechanic's workshop. Fingers crossed it just needs a thorough bleed with a separate priming pump.
 
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Turn it into a 2 man job

Prime system for 30 seconds, then get someone to crank as you continue to pump fuel, as soon as it fires get it out for a good run! :thumb:
 
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