Fuel Filter Change - 2.4l 5/2005 ANH10W

[Gamith]

Since there doesn't seem to be a topic for this I thought I would start one in case it helps anyone.

 

Undo the flaps covering the four bolts holding the wide 'driver side' seat to it's runners, undo the bolts (I did the fronts first and then moved the seat forward to do the rears.

Move the seat out of the way - it's quite heavy so either move it to the back or out of the van with help.

Peel away the carpet layers - you are trying to get to the section between the sets of runners in the middle of the van. I have a top carpet, a normal carpet and then the underlay. I ended up cutting the under carpet and underlay in different locations to get it all out.

Once you have the area clear there are 4 8mm bolts holding the panel down.

[Gamith]

Once the panel is out of the way you can see the top of the fuel pump with an electrical connector and the fuel line.

Remove the electrical connector first - the way it works is you squeeze the top of the clip and then wiggle it loose - the grey cap is to hold the wires in place.

[Gamith]

Then it's the turn of the fuel connector - lever the yellow locking 'thing' out of the way an remove it - just pulling it back won't help you.

Loosen and then remove the 8 6mm bolts holding the metal cover down

Then it's a bit of a juggling act to:

1. remove the fuel fuel connector and put your thumb (or finger) over the hole to stop it leaking too much
2. lift the metal cover out of the way
3. remove the fuel filter - this needs a little care as the coarse filter sticks out one way and the float sticks out another - I pushed the float arm in a little help
4. Turn the filter upside down to let it drain and
5. Let the fuel connector drain into the tank

You can then see how much debris is in the tank

 

[Gamith]

Once the filter has had a chance to drain (tuning it around helps) you can then remove the top and bottom caps.

I used a set of trim removal tools and a screwdriver to move the cap retaining clips out of the way - not easily captured in pictures.

Once the top cap is removed there is a connector to the pump to disconnect.

The bottom cap holds a rubber cap to the bottom of the pump - this can fall off very easily

There are then several items to swap over:

1. top cap with fuel float
2. bottom cap with coarse filter
3. a silver regulator to the side of the bottom cap

[Gamith]

The coarse filter doesn't actually seem to filter anything but it would be worth a look just in case.

[Gamith]

After that, as the saying goes, fitting is the reverse of removal.

1. Line up the holes in the cover and do them all loosely until they can all be tightened
2. connect the fuel line, and put the yellow clip back to secure it
3. re-connect the electrical plug in the socket

turn the engine on to test - expect 5 to 10 seconds of turnover before it fires - you should also hear the motor working (I couldn't as I have removed the front lambda sensor so it sounds like a tank at the moment 🙂 )

[Barry West]

3 hours ago, Gamith said:

Once the filter has had a chance to drain (tuning it around helps) you can then remove the top and bottom caps.

I used a set of trim removal tools and a screwdriver to move the cap retaining clips out of the way - not easily captured in pictures.

Once the top cap is removed there is a connector to the pump to disconnect.

The bottom cap holds a rubber cap to the bottom of the pump - this can fall off very easily

There are then several items to swap over:

1. top cap with fuel float
2. bottom cap with coarse filter
3. a silver regulator to the side of the bottom cap

Did you buy original or get the blueprint option with a minor design tweak 

[Gamith]

27 minutes ago, Barry West said:

Did you buy original or get the blueprint option with a minor design tweak 

I got a 'J1332091' from Autodoc - this one I think: https://www.autodoc.co.uk/herthbuss-jakoparts/1376214 it seemed to match the original that I got out - though I suspect that the previous one was also a clone of some sort as I couldn't find any sign of a manufacturer on it.

[dag]

Brilliant thanks for doing that.

more of this needed from us all.

thanks

 

[dezufo]

Thanks for this write-up, I have book marked it in case I ever need to do the same

[Gamith]

There is a very good video that goes through it all, but I just took pics. 🙂

Ah, found it.