So I ordered viton O-rings for the 01 model shaft from McMaster Carr, and now have to solve the leaking at the top. The original copper ring just doesn't seal anymore and so I have taken it off and made measurements. My vernier measurements are 18.2mm inside and 21.4 mm outside. I tried making a new ring out of gasket material but it leaks too. I'll find something.

What a silly pain.

__________________
Where there's a will there's a way
1978 300D

if I'm not filtering the fuel properly, how come the filters getting clogged up slows me down?

__________________
John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

You're burning dirty fuel, it gets circulated and eventually the filters will get clogged up.

Attached Thumbnails

 

__________________
83 SD

84 CD

How come you don't recognize the correct answer when told?

Maybe that o-ring is just a decoration and actually serves no useful purpose.

Hey! I believe you, I'm just throwing info out there. I'm glad to know I'm an idiot about these things. I've got a brand new box of o-rings and I'll be installing them on ALL my and my customer's cars. everything I read about these cars said the 01 base had no o-rings, just the 02, now I see that the 01 has one o-ring, and the 02 has 2 o-rings. yes?

__________________
John HAUL AWAY, OR CRUSHED CARS!!! HELP ME keep the cars out of the crusher! A/C Thread
"as I ride with my a/c on... I have fond memories of sweaty oily saturdays and spewing R12 into the air. THANKS for all you do!

My drivers:
1987 190D 2.5Turbo
1987 190D 2.5Turbo
1987 190D 2.5-5SPEED!!!

1987 300TD
1987 300TD
1994GMC 2500 6.5Turbo truck... I had to put the ladder somewhere!

Island300, Sent you a pm about your seal. Also, see my last reply above. I found a solution for 4 bucks at Autozone.

__________________
"Knowing is not enough, we must apply.
Willing is not enough, we must do." Goethe

***********************************


1951 Chevy 3100

2003 Indian Chief Roadmaster

1983 GMC 1 ton Dually

1982 Chevy 1 ton Dually, service body (sold)

'90 GMC Suburban 6.2 "SS Veg-Burban"
(single tank WVO\diesel conversion) SOLD

'81 300D ~ Mama's car...my job (now my car)(but still my job) SOLD

'83 300sd ~ rescue car SOLD

2005 Ford Taurus (Mama's new car)(NOT my job!)

You should be able to get a copper washer the same size or close to it from an auto parts store. My local one has bubble packs of them near the oil change stuff, and a drawer full of bulk ones in assorted sizes at the parts counter. A crush washer with a 3/4-inch center hole would probably be close enough. The outside diameter is not critical.

The reason yours doesn't seal anymore is the copper has become work hardened. If you're really stuck for a replacement, heat it with a torch until it glows red and then let it cool. This should anneal it and make it soft again.

This has become a PIA and yet silly problem to deal with. To think a washer would cause such grief. I went today and bought the #30 cap thread gasket that had been recommended, which was plastic, and that leaked like it wasn't even there. I also sized and bought a fiber gasket that fit very well, but it saturates and leaks actively too.

I got so frustrated I took a file and lightly filed the top of the housing to make sure it wasn't deformed or dented in some way, and found there had been a few depressions and divits that I cleaned up, but this has gotten ridiculous. It still leaks. I'm tempted to order Viton orings in the right size since I could be certain they would crush to fill gaps and would seal, but McMaster sells them in bulk and they are a bit pricey.

I live on an island with no auto stores but next time I'm off island I'll maybe buy the copper set that has been recommended. Jeez, it's a damn washer for a low pressure fuel situation...it's easier to replace the brake pads.

__________________
Where there's a will there's a way
1978 300D

Hopefully in the (near) future you'll obtain and consult an FSM before you start working on these cars, especially if you charge folks to do so.

Attached Files

fuel filter:0780.pdf (429.8 KB, 139 views)

__________________
83 SD

84 CD

Did you try annealing the copper washer like I suggested? Unless it's really badly deformed that may get you a leak-free seal again. When the copper gets crushed it work-hardens, and pretty soon it's too hard to deform when you tighten the bolt. Annealing it undoes the work hardening and makes it soft again.

Thanks for the suggestion, and no I haven't tried it yet. Will a heated and softened copper washer work as well as a new one? Wonder what the atomic reality of this hardening and softening with heat is as I have heard about this before. Maybe I'll look that up tonight.

__________________
Where there's a will there's a way
1978 300D

^ Yes.
http://en.wikipedia.org/wiki/Annealing_(metallurgy)

Most folks can simply replace the existing item.

I use a #30 cap thread gasket, it'a an SAE measurement, 3/4 inch ID. The older ones are made of composite material and work very well.

__________________
83 SD

84 CD

It should work. Of course if you keep annealing and re-using the same washer, eventually the washer will get too thin, but right now the main problem is probably that it's just hardened too much to crush easily.

If you're curious you can demonstrate the work hardening effect pretty easily with a length of solid wire -- like copper house wire, or even a steel paper clip. Flex it repeatedly in the same spot and you'll feel it get stiffer; if you keep going it'll get so hard it'll fracture.

This is why you see stranded wire used in applications that see flexing and vibration -- like in cars. If the wiring in your car was solid, engine vibration would cause it to gradually harden and eventually break at connection points.

I just went through this thread again. wow, what a bunch of Gnashing of teeth and wringing of hands just to change a filter.

The drama, the suspense, this is like a soap opera . Who shot JR? (those of you old enough to remember)

It almost seems like maybe this aluminum washer is another Unobtanium part by how difficult it is to find one. I think it Fastlane it is listed as a hollow Bolt seal Ring.

It seems like it would be easier to find the second version of the filter housing/head.

First version part# 615 092 01 08 uses one rubber "O" ring on bolt shaft and 1 aluminum washer under bolt head.

__________________
there were three HP ratings on the OM616...

1) Not much power
2) Even less power
3) Not nearly enough power!! 240D w/auto

Anyone that thinks a 240D is slow drives too fast.

80 240D Naturally Exasperated, 4-Spd 388k DD 150mph spedo 3:58 Diff

We are advised to NOT judge ALL Muslims by the actions of a few lunatics, but we are encouraged to judge ALL gun owners by the actions of a few lunatics. Funny how that works

^ If Charlie runs out of "02" filter heads, let me know. Mine include all new washers for all banjo bolts that need 'em and and two new "O" rings.

__________________
83 SD

84 CD