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Old 03-03-2015, 09:07 PM
Join Date: Dec 2007
Posts: 5,061
How to install washers for new fuel filter on 1991 560SEL?

OK, finally was able to remove the fuel filter/fuel pump assembly from the 1991 560SEL. BTW, a 3/4" PEX plumbing plug works GREAT as a stopper in the end of the fuel line coming from the fuel tank! Combined with a fuel line clamps from NAPA and I didn't have to siphon the tank or drain it from underneath the car!

Now, onto more pressing business. Of course I have to remove the 17mm acorn nut on the rear most fuel pump and replace the copper crush washers (they are leaking fuel BAD). I'm also going to change out the fuel filter. The new fuel filter came with three steel washers, two washers are thin and one washer is more of a flat washer. Question: where do these washers go?

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Old 03-04-2015, 10:29 AM
Registered User
Join Date: Feb 2007
Location: los angeles
Posts: 687
You should only have copper washers per original factory replacement, it would take 2 washers each and additional 1 washer at line connection where pump joins filter,5 total, if you bought aftermarket washer you should be able to use those, some pumps may come without check valves in pumps, then you would use a smaller washer at check valve to pump connection 1 for each pump check valve 2 total, grand total of 7 washers
5 big 2 small
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Old 03-07-2015, 11:38 AM
Join Date: Dec 2007
Posts: 5,061
UPDATE: new idea for removing 17mm acorn nut!

Finally removed the 17mm acorn nut from the end of the rear fuel pump by using vice grips to stop the banjo fitting from rotating. However, I'd recommend placing rubber hose over the vice grips so that you don't scratch/gouge the banjo fitting. The 17mm acorn nut came right off with no effort, however I damaged the check valve nut by using a cheap chinese made 17mm open end wrench. Never again.
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Old 03-08-2015, 12:09 PM
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Join Date: Mar 2003
Location: Southern California
Posts: 2,157
It's best to have new copper washers, which function as gaskets, but the old ones can be reused with a little work. Put some 400-600 paper on a flat surface like a piece of glass and wet the paper with mineral spirits. Dress them until the surface is smooth.

The copper is soft and will fill the micro gaps to from a seal. The same thing can also be done with the oil drain plug copper gasket.

The last time I bought a Bosch replacement fuel filter the copper gaskets were missing from the box, so Phil mailed me a set.


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