New Fuel Filter - Won't start now :-(

[transitdude]

Hi All,

Just installed the new Fuel Filter and now the 2.0L Duratec Diesel doesn't want to start anymore. (It's a 2003 model 100 T260)

Admittedly the first attempt I did not fill the filter with diesel so on the second batch of attempts made sure it was filled but makes no difference.

Have tried the old filter back in to no avail.

Any suggestions?

[AndyG]

Sounds like you've simply got air in the system

Fit the new (genuine) filter again making sure it is seated correctly and of course full of diesel

Then slacken the injectors one at a time and crank it over until the air has been pushed out and it will probaly start before you get to the last one

[transitdude]

Thanks

I you mean these fellas? - is it just a case of loosening those nuts and the injectors come loose?

[AndyG]

Yep the big nuts on the end of the pipes going onto the injectors They only need to be slackened off a bit so the air can escape and you see diesel comming out while you or somebody churns it over

WATCH OUT FOR MOVING PARTS

[transitdude]

Cheers fella, fingers crossed it will sorted it out.

One other thing, do you know what the purpose of the removable cap is on top of the fuel filter support housing. It seems to give access to topping up the fuel filter once it's installed?

[Nighthawk]

The injector pipes shouldn't actually be undone once they've been torqued when fitted, but you'll probably be ok if you can undo them without spinning the injector itself.

The system was designed to use a vacuum pump to prime the low pressure system.

the bung you describe sounds like the blanking plug fitted in place of the hand primer.

[transitdude]

ahh well, managed to get it going for a short time this morning using this method but once I turned it off it wouldn't come back on

tried cracking the injectors again but to no avail... and the battery just went flat. there is diesel coming from the injector though when they are loosened.

is there anything else I need to bear in mind or try to get my van going again?

[Nighthawk]

after the system has been bled, it's best if you give the vehicle a drive for a couple of miles.
it recharges the battery and flushes any trapped air air from the fuel pump.

[transitdude]

I'm a bit concerned.

I've followed some instructions from the Ford TIS manual which suggests introducing a piece of clear tubing between the fuel filter and the main pipe from the petrol tank (with a manual pump in between). I pumped as it said so fuel is clearly transfered into the filter but when trying to start the fuel doesn't appear to be moving through the pipe.

Would I be correct in the assumption that the fuel pump isn't doing its job?

I can't believe the trouble a darn fuel filter is causing me here!

[transitdude]

All fixed now.

There was a large airlock further down the fuel line. Removed one of the pipes and used the pump prime tool verify fuel could get down there.

Started ok after that. Bonus!

Banished all fear of a broken fuel pump

[AndyG]

Well done
I love it when it all goes right AND you post back to confirm

[transitdude]

Cheers, you wouldn't believe how close to the point of giving up I was. Cracking those injectors just wasn't doing it on this occation.

I was fingering the yellow pages for a bit planning my mechanic help call tomorrow

My advice to any dudes contemplating a fuel filter change would be to follows these simple practices:

# 1 - Make sure your engine is fully warmed up before attempting the fuel filter change.

# 2 - Make sure your fuel filter is full of fresh diesel before installing into place.

# 3 - Leave your engine running for several minutes once installed and when happy its ok, take it for a long run.


TTFN

[Nighthawk]

great stuff.

you'll be able to lend your filter changing expertise to other forum members now