While still trying to track down my air leak in the fuel system, I decided to re-tighten the banjo bolts on the secondary filter housing. The banjo with the fuel running from the filter to the IP snapped in half while tightening. I have searched the parts and can't find a replacement. This bolt has a 17mm head.

Anyone know where I might be able to locate one?

Thank you!

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'85 300TD- current toy
'04.5 Cummins- Daily Driver
'70 Chevelle- under construction
'63 Split Window- under construction

The Junkyard or the Dealer.

You will also need new Crush Washers or you will likely snap another one if you try to stop a leak by tightening it.

I don't know if Hydraulic Shops carry them in the proper size or not.

Also the Secondary Filter is on the pressure side of the System. It is unlikely that anything on that side of the System would cause an Air Leak.

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84 300D, 82 Volvo 244Gl Diesel

If you know the bolt length, diameter, and thread size, couldn't you just buy a regular bolt and drill it out? Just wondering if it would be simple enough or not??

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1983 Mercedes 300D 376K (diesel commuter)

With out a drill press drilling down the center of a Bolt would be challenging.
Drilling the cross holes on a Drill Press would even be a little harder without a Drill Press Vice.
The drilling into a Grade 5 Bolt requires a reasonable quality share Drill Bit.

Not impossible to do but in My case if I hustled down to the Junk Yard it would even take me less time to remove one and come Home then it would to round up the Tools and Drill one out; and I have a Lathe that would make drilling it out even easier.

And, getting a New Bolt to Drill could cost you $2 each.

There must be one of our Members in His area that has a parts Car that could get on to Him.

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84 300D, 82 Volvo 244Gl Diesel

Yes, junk yard.

You need two crush washers, one on either side of the banjo bolt itself.

I have one, but it's part of a newer style fuel filter head unit.

What are you willing to pay for it?

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83 SD

84 CD

Radiator shop or a brake shop. Hydraulic shops won't have it.

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$60 OM617 Blank Exhaust Flanges
$110 OM606 Blank Exhaust Flanges
No merc at the moment

I think He broke one of the ones on the side because He said the Bolt has a 17mm Head on it. I beleve the Center Filter bolt has a larger head.

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84 300D, 82 Volvo 244Gl Diesel

I understand which bolt he's referring to, the other 17mm is the three way return bolt.

Crush washers on either side of the fitting, yes, the spin on filter bolt is larger, mine is 24mm. The bolt from the lift pump is 19 mm.

Attached Thumbnails

 

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83 SD

84 CD

That is a steel bolt going into an aluminum housing. that is some serious torque to snap it off, wonder what damage was done to the threads on the housing?

I agree with getting a bolt from PNP. I think the whole filter housing is around $15, but you pull it. If you do replace the housing make sure in the part#, the 2 #`s from the last is "02". don`t need the crush washer under the center bolt head, just the 2 "O" rings.

Charlie

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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

I found one at my local German Auto repair shop. They searched through a few random parts bins and found one for me. Free of charge too. Got some crush washers from a local hydraulic shop, who I figured would have the bolt, but they didn't have the right size.

I really wasn't torque-ing it too hard. Just snugging it down. Snapped right where the cross holes are. The threaded portion was still in the housing and spun right out. Got lucky on this one I guess.

Thank you all for the suggestions and help. My next stop was the junk yard.
I can only imagine trying to drill a grade 8 bolt. HA, have to video tape that one and edit out all the bleeps!

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'85 300TD- current toy
'04.5 Cummins- Daily Driver
'70 Chevelle- under construction
'63 Split Window- under construction

If it still has the original Aluminum Cursh Washers on it I bet the Previousl Owner it the one who over tightened it. The Aluminum ones cannot be reused as often and would take more tighening to stop a leak.

I made a central Filter Bolt for the Below Baldwin Filter Mod.
http://www.peachparts.com/shopforum/diesel-discussion/225004-lower-micron-fuel-filter-mod.html

But, I heated the Bolt up Red Hot and cooled it slowly to soften it (no need for high strength for this application) before I drilled it and I had a Lathe to allow me to drill down the exact center.

It would have been a trying job for Me on a Drill Press and nearly impossible for Me to do it with a Drill Motor.

I have met extremely well cordinated People who can do that sort of thing with a Drill Motor in their Hand but I am not one of them.

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84 300D, 82 Volvo 244Gl Diesel

I've got an extra set of secondary fuel filter banjo bolts if this comes up for someone in the future. The last time I went to the junk yard with Charlie we pulled a newer fuel filter assembly (the one with two o-rings down the center bolt), and it came with all the bolts, heh heh.

Kurt

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- '79 240D - engine swap complete! Engine broken in! 28-31 mpg! Lovin' the ride!
- '86 190D (W201-126) - 2.5 NA engine, 5 speed, cloth interior, manual climate controls, 33-34 mpg (sold to forum member).

That's a pretty slick mod, Diesel911. I do not have a drill press and would not attempt it free handed. I've drilled and tapped a few things in the past, but nothing like that!
If I can ever get this car to run, I would most likely add a fuel/water separator at some point. Actually last night I was looking at DIY add-on filters for my truck. Your mod will also accept the CAT 2 micron filter, and I believe a Donaldson as well.

Speaking of crush washers, where is the best place to find replacements? The parts stores like NAPA don't carry them. A lot of asian oil plugs take them, but nobody seems to carry them. What gives?

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'85 300TD- current toy
'04.5 Cummins- Daily Driver
'70 Chevelle- under construction
'63 Split Window- under construction

I bought one of those copper washer assortments from Harbor Freight. If they are a little tight I take a File and enlarge them.
So far I have not come up short.

People say ACE Hardware has some; but they are likely US sizes.

You alread know about Hydraulic Shops.

Copper Washers can be re-used a bunch of time and after that they can be heated Red hot and allowed to cool. After that they are soft again. So you can get a lot of use out of a Copper Washer.

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84 300D, 82 Volvo 244Gl Diesel

I also bought that kit from Harbor Freight. Only problem I had with them was on the lift pump, fitting in the slots. They are way thicker than the stock ones.
With my air leak, I am thinking of pulling the lift pump again and checking all those fittings. Has to be where my bubbles are coming from.

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'85 300TD- current toy
'04.5 Cummins- Daily Driver
'70 Chevelle- under construction
'63 Split Window- under construction