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Old 02-08-2004, 01:48 PM
Registered User
Join Date: Nov 2003
Location: Indy
Posts: 37
fule filter line leak

1992 500E:

I just replaced my fuel pressure regulator, and decided to also replace the fuel filter, while the pressure was off.

The front connection to the filter has a banjo bolt, and I can't get it to stop leaking. The new Bosch fuel filter did not come with a new copper washer that goes on the filter side (of the banjo bolt), so I first tried to use the one from the old Mahle filter. I ended up with a small stream spraying from where the washer is. I then tried an oil plug washer, which is slightly smaller, and have the same problem.

I'm afraid of tightening the bolt too much, but maybe I am just being too conservative.

Any ideas?

Thanks in advance,

Monty Ewing

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Old 02-08-2004, 02:58 PM
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Join Date: Mar 2003
Location: Southern California
Posts: 2,196
As I recall from the last time I changed my fuel filter, the Bosch filter is supplied with two new copper rings for the banjo bolt - could be one was removed. Talk to your supplier.

The old rings can be reused. You will notice that the sealing surfaces are galled. Place a piece of 220 to 400 paper on a flat surface and wet it with mineral spirits. Then dress both sides of the copper seal rings until the galling is removed and the surface is flat and smooth.

This technique can also be used to get several uses from the oil pan plug copper seal ring.

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Old 02-08-2004, 03:45 PM
Registered User
Join Date: Nov 2003
Location: Indy
Posts: 37
fuel filter leak

Thanks for the tip. My new Bosch filter had no washers included. I guess thats the problem with mail order parts. I will try the sanding idea right away. Hopefully, that will get me on the road.
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Old 02-08-2004, 06:24 PM
Registered User
Join Date: Nov 2003
Location: Indy
Posts: 37
fuel filter washers

Sanding the washers worked like a charm. Thanks Duke!

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