Fuel filter upgrade - PeachParts Mercedes-Benz Forum

Alec300SD · #1 06-24-2017, 07:26 PM

Inspired by Diesel911, cho and others, I did a fuel filter upgrade on my 78 300SD and my 83 300SD.

Better fuel filtration, down to the two micron level, can be achieved using a CAT 1R-0750 fuel filter.
(Even better fuel filtration, down to the one micron level, can be had with a Nicktane 1 Micron 100% Synthetic Microglass Tall Fuel Filter from nicktane.com.)

My requirements for this upgrade for my vehicles:
1) Update to a “02” stock fuel filter head (6150920208).

2) A relocating plate (plus a spacer for cars with brackets attached to the original fuel filter head) and the mounting hardware needed to relocate the updated “02”
stock fuel filter head (6150920208) to allow the longer CAT 1R-7050 or Nicktane tall fuel filters to clear the lower webbing of the power steering bracket (6172360330).

3) A thread adapter (with central M14 X 1.5mm threads and with the correct external thread – to match the filter) is needed as well. The CAT filter has 1” X 14tpi threads.
The Nicktane tall filter has 1” X 12tpi threads.
This threaded adapter has to be custom made as there are none commercially available.

4) A crush washer (17mm X 23mm X 1.5mm) used between the threaded adapter and the updated “02” stock fuel filter head to protect the boss on the fuel filter head from damage.
(14mm X 23mm X 1.5mm would be ideal, but is not readily available)

5) The updated “02” head stock hollow fuel bolt uses two o-rings. I wanted to use Viton o-rings to be able to use biodiesel.
I used a 2.5mm X 14mm Viton o-ring for the top groove and a 2mm X 10mm Viton o-ring for the bottom groove of the hollow fuel bolt.

6) No modification of the stock “02” fuel filter head is needed when using the CAT 1R-7050 filter.

7) Some of the webbing on the Stock “02” fuel filter head must be removed to use the Nicktane fuel filter as it has a larger diameter than the stock filter.

8) New flexible clear hard lines need to be installed (6150704232, 6150704032, and 6150705632)

9) Also needed are two aluminum crush washers 14mm X 18mm X 1.5mm (007603014100) for the larger diameter fuel head inlet line, and 8 aluminum crush washers
12mm X 15.5mm X 1.5mm (007603124205) for the other two clear hard lines ( 12mm X 15.5mm X 1.5mm is an odd size, so 12mm X 16mm X 1.5mm would also work).

10) And of course, the upgraded fuel filter is needed as well: a CAT 1R-7050 to be used with the 1” X 14tpi adapter, or the larger diameter Nicktane filter to be used with the 1” X 12tpi adapter.

Alec300SD · #2 06-24-2017, 07:28 PM

For my own vehicles, I wanted a simple, durable upgrade that could be easily installed or removed with basic hand tools.
The upgrade needed to be revertable back to stock on the road if the need arose.

Because people in other past fuel filter upgrade threads have expressed interest in purchasing the components needed for a fuel filter upgrade,
I also wanted to be able provide at least a few kits for sale to forum members to defray a portion of the development costs.

My first design for a 1" X 14tpi adapter involved taking a 1" X 14tpi bolt, drilling and
tapping for M14 X 1.5mm threads, and cutting off a 0.5” section of the tapped bolt.
Two recesses were drilled on the flat faces to allow the use of the 90 degree bent pins of a pair of snap ring pliers to tighten/remove the adapter.

The first prototype had a few issues: the bolt was hardened so it was difficult to work on it with cutting tools (the drill bit wandered and the hole was drilled off-center),
the threads of the bolt were quite coarse and irregular, and it is difficult to tighten the adapter to the hollow fuel bolt.

The second design idea was to modify a ready-made gun cleaning solvent adapter with pre-existing external 1” X 14tpi threads (designed for use with a CAT 1R-7050 fuel filter).
The center of the high carbon steel thread adapter was tapped to M14 X 1.5mm treads and all but 2mm of the knurled portion was removed.
This prototype also has a few problem: it costs more, it is difficult to tighten the adapter to the hollow fuel bolt,
and the jaws of the pliers used to tighten/remove the adapter could damage the adapter and the fuel filter housing.

The third and final design idea was to have a custom adapter made with a metric hex at one end to allow
one to easily tighten/remove the adapter with a metric socket or wrench.

Realizing I couldn’t do this on my own, I enlisted the help of others and was able to obtain one prototype each
of a M14 X 1.5mm to 1” X 14tpi stainless steel thread adapter, and a M14 X 1.5mm to 1” X 12tpi stainless steel thread adapter.
The hex portion of each adapter is 19mm.

With functional prototypes in hand, the next phase was to make the relocating plate and spacer bar.

Alec300SD · #3 06-24-2017, 07:29 PM

The first iteration of the relocating plate was too small (0.25"’ X 2.5” X2.5”), and when installed caused kinks in
one of new clear hard lines (return line from the overflow valve on the IP) and a leak on the banjo nipple of the new clear hard line connecting to the inlet to the fuel filter head.

The final design of the relocating plate was made from a piece of 0.25" X 2.5” X 4’’ aluminum stock.
The mounting locations on the relocating plate assure that the new stock clear hard lines can be used without binding.

My initial idea for the bracket spacer was to use a 1” X 2” X2.5” piece of aluminum bar with mounting two holes,
and sandwiching it between the relocating plate and the power steering bracket.
When mocked up, this looked a bit unwieldy.
For my final design, I ended up going with a 1” X 1” X 2.5” aluminum spacer instead.
When mounted on top of the relocating plate it acts as a clamping bar.

I countersunk the mounting holes and filed smooth the cut edges on the relocating plates and spacers.

Alec300SD · #4 06-24-2017, 07:32 PM

The “02" heads were pulled from the junkyard and reconditioned.
They were soaked in Berryman carburetor cleaner for a week, cleaned with nylon brushes,
rinsed in HPR diesel fuel and then wiped dry with shop towels.

The sealing surfaces were reconditioned…essentially by lapping them on a glass shelf with clear power steering pump fluid (as a cutting agent) on 220, 320, and finally 400 grit 3M wet/dry sandpaper.

Because of the extra work to grind down the webbing on the fuel filter head in order to fit the Nicktane fuel filter,
and the higher cost of the less readily available Nicktane fuel filter, I decided to nix further development of M14 X 1.5mm to 1” X 12tpi adapters.

Alec300SD · #5 06-24-2017, 07:33 PM

On the 78 300SD, I installed the CAT 1R-7050 fuel filter with the 1” X 14tpi adapter.
On the 83 300SD, I installed the Nicktane filter with the 1” X 12tpi adapter.

New clear hard lines and crush washers were installed.
The updated “02” fuel filter heads were used.
I splurged and ceramic coated the power steering bracket and the fuel filter head for the 78 300SD
Webbing was removed from the fuel filter head used for the 83 300SD.
New Viton o-rings were used on the fuel filter hollow bolts.

Hex bolts and spring washers were used to attach the glow plug harness bracket, clamping bar/spacer and
relocating plate to the power steering bracket on the 78 300SD.

The 83 300SD has a vacuum output line bracket that mounts to the fuel filter head.
Allen head bolts and spring washers were used to mount the supporting bracket of the vacuum output line,
the clamping bar/spacer, and the relocating plate to the power steering bracket on the 83 300SD.

Split ring lock nuts and spring washers were used with the original fuel filter head bolts to secure the “02" fuel filter heads to the relocating plates.

Alec300SD · #6 06-24-2017, 07:34 PM

I ordered five more of the custom stainless steel M14 X 1.5mm to 1” X 14tpi adapters that allow fitment of the CAT 1R-7050 fuel filter, and gathered together the components for upgrade kits.

Five complete turnkey CAT 1R-7050 filter upgrade kits are for available for purchase.

This is a one-time offer.
I have no plans to fabricate any additional kits because of the time required and high cost of materials.

Cost per kit is $150 including CONUS shipping via USPS.
The kit will fit any OM61X that uses the 6172360330 power steering bracket and a “01” or “02” fuel filter head.

Each kit consists of:
1) one 14M X 1.5mm to 1” X 14tpi stainless steel threaded adapter,
2) one 17mm X 23mm X 1.5mm aluminum crush washer
3) one CAT 1R-7050 fuel filter,
4) one reconditioned “02” fuel filter head with its hollow bolt (24mm hex head),
5) three upper 2.5mmX 14mm Viton o-rings, (one to install and two spares) for the hollow bolt on the “02” fuel filter head
6) three lower 2mm X 10mm Viton o-rings, (one to install and two spares) for the hollow bolt on the “02” fuel filter head,
7) one aluminum relocating plate (approximately 0.25” X 2.5” X 4”),
8) one clamping bar/spacer (approximately 1" X 1” X2.5”),
9) two used M8 X 1.25mm X 45mm (6mm Allen hex head) bolts to mount the reconditioned "02" fuel filter head to the relocating plate,
10) two used spring washers,
11) two M8 X 1.25mm (12mm hex) copper coated split ring lock nuts,
12) two 14mm X 18mm X 1.5mm aluminum crush washers,
13) eight 12mm X 16mm X 1.5mm aluminum crush washers,
14) one Hebmuller primary fuel filter (0014777901),
15) one 16mm X 20mm X 1.5mm aluminum crush washer for the primer pump.

Send me a PM if interested.

Diesel911 · #7 06-25-2017, 12:44 AM

Three thumbs up!

greazzer · #8 06-25-2017, 12:56 AM

Rather Impressive !

MTUpower · #9 06-25-2017, 12:03 PM

So this kit is plug and play? Can a good DYI'er install themselves and how long would it take? If so then PM me and you have a buyer.

Alec300SD · #10 06-25-2017, 05:41 PM

Quote:

Originally Posted by MTUpower

So this kit is plug and play? Can a good DYI'er install themselves and how long would it take? If so then PM me and you have a buyer.

Yes, this DIY job is pretty much plug and play…by design.
It should take about 3 or 4 hours from start to finish on average.

PM sent.

I’ve also included detailed instructions below for kit purchasers:

Disassembly:
1) First, thoroughly clean any fuel union you will disturb with a blast of brake cleaner.
You don’t want any grit getting into your injection pump.

2) Remove cigar hose end from metal fuel return line to tank.

3) Remove fuel line end from inlet to lift pump, and reattach this fuel line end to the metal return line to tank.

4) Use line wrenches to remove hollow bolts holding the fuel inlet (19mm), fuel outlet (17mm) and fuel return line (17mm) banjo fittings to the old fuel filter head.

5) If you have a vacuum pump output hard line bracket attached to the old fuel filter head, loosen the fittings
at the vacuum pump and also where it attaches to the plastic vacuum supply line.
This prevents inadvertent breakage of the bracket.
If no vacuum pump hard line bracket is attached to the old fuel filter head, proceed to step 6.

6) Remove the old secondary fuel filter from the old fuel filter head.

7) Clean the Allen head bolts attaching the old fuel filter head to the power steering bracket with a blast of brake cleaner and cotton swabs.

8) Make sure the 6mm Allen hex socket is fully seated in the bolt (tap it in firmly until it seats),
remove the two bolts and any brackets between the bolts and the old fuel filter head.

9) If you don’t have Allen head bolts in this location use the 13mm socket to remove the hex head bolts.

10) It is recommended to replace the old clear fuel hard lines as they lose pliability, and translucency over time.
Remove the hollow bolt (17mm) attaching the banjo fitting to the injection pump fuel inlet.
Remove the fuel pressure relief valve (17mm) attaching the banjo fitting to the injection pump return line.
Detach the lift pump fuel output line.
To loosen or tighten the metal fitting (22mm) on the line that attaches to the output of the lift pump may require the removal
of the lift pump inlet nipple (19mm), and does require the removal of the primer pump (24mm old style, 17mm new style), and replacement of the primer pump crush washer (16mm X 20mm X1.5mm).

Assembly:
1) Thoroughly clean the reconditioned “02” fuel filter head (and its hollow bolt) with liberal use of brake cleaner
to prevent any potential contaminants from getting into the injection pump.

2) Dip the upper Viton o-ring (2.5mm X 14mm) in clean diesel fuel and install in the upper groove of the fuel filter head hollow bolt.

3) Dip the lower Viton o-ring (2mm X 10mm) in clean diesel fuel and install in the lower groove of the fuel filter head hollow bolt.

4) Install the hollow bolt into the recondition “02” fuel filter head.
Press in hard, it will audibly “snap” into place as it is a tight, well sealing fit.

5) Place the 17mm X 23mm X1.5 mm aluminum crush washer on the threaded portion of the hollow bolt
and loosely hand tighten the stainless steel threaded adapter.
The rounded lip of the treaded end of the adapter is in contact with the crush washer.

6) Nudge the crush washer to center it, and further hand tighten the adapter.
Snug the adapter in place with hand tools (24mm wrench of the hollow bolt and 19mm wrench on the adapter).
I like to torque to about 30 to 90 degrees past tight to apply a good “crush” to the washer.

7) Place the relocating plate on the power steering bracket (black Sharpie marking on countersunk groove towards the valve cover).

8) Place the clamping/bracket bar on top of the relocating plate (black Sharpie marking on countersunk groove towards the valve cover).

9) Use your old fuel filter head mounting bolts and old spring washers to loosely attach the old brackets,
clamping/spacer bar and relocating plate to the power steering bracket.

10) Reattach the metal vacuum pump outlet tube fittings to the vacuum pump and the plastic vacuum line (if you have this item).

11) Tighten the bolts attached in step 9.

12) Place the used spring washer from the kit on the used Allen bolts from the kit and place them through
the bolt holes of the reconditioned “02” fuel filter head.
Attach this assembly to the rear of the relocating plate with the split ring lock nuts from the kit.
Tighten the nuts and bolts with your 6mm Allen hex socket and 12mm wrench.

13) Loosely attach both of the clear hard line’s banjo fittings to the injection pump, re-use your old hollow
bolt (17mm) and fuel relief valve (17mm) and the 12mm X 16mm X1.5 aluminum crush washers from the kit.

14) Loosely attach the metal fitting of the lift pump outlet clear hard line to the lift pump outlet nipple.

15) Loosely attach the clear fuel return hard line (and fuel filter head output line) banjo fitting to the reconditioned
“02” fuel filter head with your old hollow bolts (17mm) and 12mm X 16mm X 1.5 aluminum crush washers from the kit.

16) Loosely attach the clear fuel input hard line to the fuel filter head with your used hollow bolt (19mm) and
the 14mm X 18mm X 1.5mm aluminum crush washers from the kit.

17) Coat the rubber seal of the new EMPTY CAT filter with clean diesel fuel and spin it on to the new threaded adapter of the fuel filter head.
Do not fill the filter with fuel, use the primer pump to fill the filter with clean filtered fuel (step 23).
Prevent grit from entering your injection pump.

18) Tighten all the clear hard line fittings.
On the banjo fittings, counterhold the nipple of the banjo fitting with the thumb of one hand when applying the
final “crush” torque so that the fittings don’t rotate and kink the clear hard line.

19) Install the primer pump and its new crush washer (16mm X 20mm X 1.5mm) from the kit

20) Install the lift pump inlet nipple.

21) Replace the primary fuel filter with the new Hebmuller primary fuel filter enclosed in the kit.
Replace the rubber fuel hose, if desired.
Tighten the fuel hose clamps.

22) Reattach the cigar hose to the metal fuel return line and tight its hose clamp.

23) Prime your new fuel filter and injection pump fuel feed circuit.
It takes about 200 strokes of the primer pump, keep pumping until you see no air in the clear fuel return line at the fuel filter head.

24) Start your engine.
After a few minutes, there should be no air in the clear hard lines when the engine is running (or after prolonged shutdown).

Let me know if I missed anything and I'll edit the instructions.

Clemson88 · #11 06-25-2017, 12:40 PM

Strange enough I was looking through the thread on this subject which is found in the DYI archives just this morning. I became curious about the cost of such an upgrade and even looked at the prices on Cat filters.

I don't know if I've ever had any water in my fuel because I change the fuel filter at 6-8000 miles which equates to two oil changes. Imo, they are cheaper than pushing the envelope. I have no idea where that envelope is and don't care.

I can't add another step to moving a 617 to a gas body and rejuvenating the interior right now but I hope to be a customer next summer. I have a few fuel filters now and will probably use them which will give me time to do an overall to the air conditioning.

That's a great write up and very impressive. This thread is gold and should be added to the 'Want adds,' here and the DYIs.

OM617YOTA · #12 06-25-2017, 05:34 PM

Nice kit! Much cleaner than my own conversion.

Tip for those buying CAT filters, your local CAT dealer may be less expensive than an online source. Mine sure is.

Alec300SD · #13 06-25-2017, 05:56 PM

Quote:

Originally Posted by OM617YOTA

Nice kit! Much cleaner than my own conversion.

Tip for those buying CAT filters, your local CAT dealer may be less expensive than an online source. Mine sure is.

Thanks for the high praise!

Agreed, I purchased mine from the local CAT dealer, Peterson Tractor in San Leandro, CA, on my way into work one morning.
It took all of 10 minutes to purchase and receive them in hand from the parts counter.

Alec300SD · #14 09-30-2017, 04:18 PM

Link to classified ad.

http://www.peachparts.com/shopforum/mercedes-used-parts-sale-wanted/386988-fs-cat-1r-7050-fuel-filter-upgrade-kits-om61x.html

Alec300SD · #15 01-03-2021, 06:46 PM

Two kits remain available as of this posting on January 03, 2021.
One kit has the final design of the threaded adapter, the other kit has the second prototype of the threaded adapter.