How to change Ford 1.6 TDCI HDI / Fuel Filter Replacement (DIY)

So after having previously changed my fuel filter on my 2009 Ford Focus 1.6 TDCI and finding there is no manual bleed, and being a full canister swap as apposed to a straight forward gravity fed filter change I had an air lock in the system and thus had the none start issue it appears so many of you are facing with DIY filter changes.
My Father being an ex mechanic I've learned some along the way and devised a cost effective alternative to the official equipment used by Ford in the dealership garages and put together this tutorial video to help those who are struggling with this issue.
The filter comes in a canister and is not separate so is pricey (around £40 from none dealer ) but all you will need is a 8mm socket set, a one way valve bulb, a link to which is provided in the video details, and some clear tube

[@mjat133]

Thanks for this fella. I have followed your demonstration to the letter and successfully changed my fuel filter at the first attempt for the first time in my life. And saved the garage fees. Thanks a lot.👍

[@AntonLippek]

Great stuff :) glad the video is helpful

[@ronm3671]

definitely the best 'how to' video on this type of fuel filter..Mines a 2010 mazda3 1.6de. exactly same set up, different car. great vid mate.

[@neiljames]

Thank you for this video, changed the filter on my 2014 Fiesta following these instructions and it worked perfectly

[@IVSpolly]

Followed these instructions to the letter. The vehicle started first time and although a little rough in idle, I took it up the dual carriageway and experienced the car better than I have ever known it. Great Job, great video, Anton. Thank you.

[@AntonLippek]

That's great to hear, glad the video was useful for you too :)

[@mrcrowley1977]

Great video and perfectly shows what I need to do changing the fuel filter in my diesel Mazda 2 which uses the same ford engine. Appreciate the details in getting the process right! Thanks!

[@chestermartin2356]

I just filled the new filter with diesel before I put it on, never had any issues, going off the comments it appears I am just extremely lucky 😂

[@scouse1967]

Had to perform this task myself a few weeks ago (in sub-zero temps) on my 2008 Focus TDCi. I even bought/purchased the "Hand squeeze pump" and some 8mm rubber tubing to manually bleed the new fuel pump. Have also replaced the EGR valve and the air filter. Added "Injector cleaner and DPF filter cleaner in my filled up to the max tank. Now my Focus is running sweet as a nut.

[@voltorb433]

Good lad , I watched this video to find out where the breather pipe off the filter harness goes. It's a little thin pipe I pulled it off by mistake, making room to get at the rail pressure sensor and now I can't see were it goes. Seems to go to the back of the engine close to the mechanical pump.

[@alessandrodrjack]

THANK YOU, AWESOME VIDEO!

[@ssheishere]

Hi, great video on the hand pump is it 8mm or 10 mm. Thanks

[@paulmarlborough]

just watched 4 or 5 videos on how to do this, yours is definitely the best, great job, I did exactly what you did and managed to get my focus started after getting an air lock in there somewhere. thanks

[@AntonLippek]

Thank you, Glad my video helped out, best wishes.

[@Golo1949]

Same with me Paul.

[@gladyssellar6408]

Great video the cap trick is what I needed to see as other guy was going on about a ford adapter kit for the hand pump

[@Golo1949]

Just changed the same filter on my Focus Mk2, after trying a few methods I saw on KZbin, I tried my own method and managed to get it to tick over and run because I needed to move it. Later it started but then stopped after a minute and wouldn't start, so I am going to try your method because I think air is still in the line somewhere.

[@Golo1949]

What I found was the filter, a no name one, was leaking from the water drain,but I couldn't see it. I bought a MANN filter and filled it with fuel first, this made it very easy to clear any air.

[@mazdamx3trackcar]

Hello mate, just want to say thanks for the video. Mine wasn’t revving past 3000rpm.Then eventually forcing itself to stall. No limp mode no warning lights. Turned key off and on and away it went. Drivable fine as long as you kept it below 3000rpm. Anyhow followed your guide. But I couldn’t get diesel out with the hand pump or by me sucking it. There might have been a soldnoid from stopping this. Anyhow I filled the filter with diesel instead. Turned key on and off 6 times as mentioned. Started up fine. Couldn’t even blow air though old filter !!!. Job fixed 👍

[@dannymccann]

The hardest part of this job is getting those fuel pipes off the filter, those clips are an absolute pig. I fill the new filter up by emptying the old filter into it, essentially that fuel has then been filtered twice anyway, starts first time every time, no messing about with pumps or anything, very clean as well. A little bit of air gets in the lines but there's plenty of fuel to pull through that after 30 seconds of running it calms down.

[@AntonLippek]

The clips are are a nightmare I agree, slipped off them a couple of times with scree drivers!

[@zeus90fly]

Good job 👍🏼

[@peletiah]

Great detailed video, explained a lot to avoid any problems with air beeing sucked into the high pressure pump. Thanks!

[@milek021]

Why not simply when there is no any more bubbles left attach outlet pipe to one way hand pump and press it more once or twice to fill the outlet instead to pour manually and probably spill around? btw good video... i will order that kind of pump, they are quite cheap... I didn't know that fuel must be pumped to system before trying to start, i was thinking that fuel pump will pump only fuel and forgot completely about air inside the new filter... You save me from serious headache and ofc u saved me some money, so BIG THANK YOU !

[@AntonLippek]

It squirts out to fast for the outlet in my punp but if you have a steady hand you could do it direct

[@JeanGodGandanne]

Ich benutze eine kleine Spritze um die Leitung mit Diesel zu füllen. Geht auch ganz gut. I use an medical injection gun to fill the fuel pipe withe diesel. Works good and is cleaner.

[@AntonLippek]

Gute idee! Great Idea :)

[@maxk7258]

Hello mate, got the same car but from 2004. The fuel filter isn't the same as yours. Is the output line at the top or at where the fuel heater is ? Thanks

[@AntonLippek]

I'm not sure about which engine you have and not worked on the mk1s before but if you follow the fuel lines the output will go feed the injectors, hope that helps

[@stevefuller1779]

If you have access to an airlinejust lightly pressurise the fuel tank and the fuel will come up the pipe, most people do not have one of tose little pumps.

[@mcarlosm]

+1 Hey there I loved the video. It is very well done and very well explained. The workshop manual as I read on a website, says to disconnect the battery for an operation of this type. I want to ask if you allow me, after changing the filter, is everything going well? Best regards

[@AntonLippek]

+mcarlosm hey, thanks for your comment, no need to disconnect battery for this as there is no chance of creating a short circuit. manuals often have copy and past instructions in so probably just that

[@bajoblajo1]

Thanks for the good lesson! I'd like to ask you, do you know where the dpfe sensor is located on ford tourneo connect 1,8 tdci 2004 year of production? DTC is P0405. Engine is HCPB. Thank you very much and God speed :)

[@luckyjack1]

This engine has not a fuel pump for supplying fuel to the engine. So your moving the key is useless. New fuel filtr must be filled , then there is no problem with starting of the engine.

[@AntonLippek]

+Honza Zezulka According to a ford garage I went to there is an electronic fuel primer from the tank, it is that which is activated by turning the key. I could not locate it but better to be safe than sorry. Filling the filter alone is not enough from experience and filling the fuel lines to the injectors is essential. If there is air between the injectors and filter the engine will not run.

[@mcarlosm]

+Honza Zezulka Hello everyone I thought that if there is fuel pump. Anyway I have to do because the savings in these difficult times is considerable. Anton heartily thank to climb this good video ;)

[@chestermartin2356]

Same, I found there was no lift pump as nothing happens when you turn the ignition with the lines detached. Just filled my new filter with fuel before it went on and had no problem

[@CarloLeonKolega]

I have a bit different fuel filter hausing, how to know where to prime from?

[@AntonLippek]

You need to prime by drawing fuel through the filter so it becomes full. Essentially you work out which pipe goes from the filter to the injectors and pull the fuel through with a priming bulb between

[@zZZSPARKZZz]

Hello I am trying this now unless I suck it no diesel coming out I suck then a bit comes out then nothing how long will it take till it comes out I took the pipe you did didn't remove filter because I just need to remove air?

[@claudettechat3144]

j'ai acheté une poire neuve, je l'ai branché en sortie du filtre et dans le bon sens, et impossible d'aspirer le fuel. j'ai donc utilisé une pompe électrique en lieu et place de la poire et c'est ok

[@dsingh2888]

Hi I'm having issue with my 2007 Ford Focus 1.8 tdci when engine is cold car misfired lots even when I'm drive.. any idea what is this. And j have to press much acceleration when I put in 1st gear other wise engine shake and stop please comments

[@AntonLippek]

D singh this could be a number of things, blocked fuel filter will do this, bad glow plugs can cause too. It could also be a restriction in the air intake, check the air filter and the pipe leading to the air box that contains the filter.

[@dsingh2888]

Anton Lippek thanks for replying mate but I have full service on my car but it's still doing it

[@AntonLippek]

D singh a full service doesn't tend to cover glow plugs, usually garages will only replace oil, air and fuel filter in a full service. if the problem only occurs while the engine is cold I'd replace the glow plugs, they are not that expensive, and easy enough to replace. They can break easily when removing though so take extra care if you are doing it yourself and make sure you spray them with lubricant such as wd40 as before each turn or so as you remove them. I replaced mine within an hour. It's recommended that they are changed every 35k miles but usually people only ever do when they completely fail. I can post a tutorial of how to replace them if you like?

[@dsingh2888]

Anton Lippek thanks my friend for good information cheers

[@dsingh2888]

Anton Lippek hi my friend another thing need to know. is deleting egr is good or bad idea ?

[@Gowingnator]

What if I have a primer bulb already fitted in the car? Would I just pump that after bleeding?

[@AntonLippek]

Gowingnator if you already have a primer bulb you just need to pump it after you change the filter until it goes hard and your good to go

[@Gowingnator]

Fuel filter was serviced July last year, so I don't plan on changing it anytime soon. I think there's just air in the line. Do I just bleed it, then pump it back in until bulb goes hard? Thanks

[@AntonLippek]

Gowingnator you just need to pump the bulb until it's hard a few times to bleed it, if it's still not starting you could have injector or glow plug issues

[@Gowingnator]

Ok thank you very much! There's carbon all over the engine bay and injectors, so could be injector problem.

[@brettlightfoot1802]

perfect again thank you!

[@klausmichaelgurke8543]

Very nice work. How many liters of diesel did you pump through the filter ? Did you fill the filter with diesel before connecting the hand pump ? I tried it once without a hand pump and it did not work with the 1,6 tdci motor.

[@AntonLippek]

Stephan S I filled the fuel filter and phoned through around 1/2. - 1 ltr before air was out, also filled the fuel line going to the injectors, that's the most important part

[@huckfinn8444]

Nice job, very good clear video.

[@milek021]

Friend, tell me, that rattling sound, where does it come from? Hydrolifters? Dangerous to use car for long time without service check?

[@AntonLippek]

Rattling is usualy something mechanical or something loose. It is dangerous to not survive regularly as the particles in the oil will lead to excessive wear. I recommended oil service every 10,000 miles or less. New service plans are usualy set now much longer but this is not good for the engine

[@beachlife2968]

What size pipe would i need to fit a 1.6 tdci focus fuel filter. Can see a lot of hand primers on ebay 8mm, would that be the right size?

[@AntonLippek]

beach life the one I used was 10mm but 8mm would work too, you might just need to play around a bit connecting it to the filter, you might be able to attach it direct without making an adapter

[@beachlife2968]

Cheers Anton

[@markkiss187]

Does anybody know how often you should change this filter

[@AntonLippek]

Every 10,000 miles if you want your engine to last I recommend. Mines covered 335k now.

[@grahamphillips3099]

how long do you need to pump for? ive been going about 20 minutes, still no fuel

[@grahamphillips3099]

Update: Draper Expert Priming Pump #43986, brand new- return valve was faulty so I wasted half an hour. Luckily I had a spare priming bulb. Started 1st time, no need to fill feed pipe or prime on the key

[@flymaxn]

how often do u change this fuel filter on this engine? Every 3 years? and what if u don't change it? Thanks Anton,

[@AntonLippek]

i change the fuel filter every 60k but if you use supermarket fuels you may find you need to do it sooner as the quality of fuel isnt as good as the likes of BP in my experince. f you dont change the fuel filter you will eventually increase the resistance in the fuel to supply to the injectors which can cause problems with them and other engine componants, the air fuel ratio may become out of balace and the burn less well. You will notice the car slow down in acceleration and also the engine management light may come on too if it gets really bad. I know they are expensive but its a job better done then not in the long run

[@ClazZie]

@@AntonLippek Yes mine only lasted about 50k, then i got engine malfuction due to bad filter.

[@zZZSPARKZZz]

Basically mine was fine. Until mechanic removed the whole filter to add injector cleaner. Now I have air and have to easy start it with bottle every day. Where can I get the green bit from if I dont wanna replace filter to connect pump to?

[@AntonLippek]

You will need to find a pice of hose, or, if you have some strong duct tape that would work. So long as you draw fuel without air bubbles and fill the fuel line it should be fine

[@zZZSPARKZZz]

Also the tappets seem extremely noisy when cold but reduce when warm. I have replaced Injector seals and turbo. I had a bigger turbo garret one which was smoking too much blue so i changed it too a smaller one from eBay which is fine BTW. What happens now it smokes black and i am concerned the original turbo was a bigger one not for this engine and it was mapped to that bigger turbo and now the air and fuel ratio is messed up until i remap again for smaller turbo. Please reply regarding tappets issue, its 1.6TDCI 90BHP 2007 model no dpf think its been removed as they are welding and 3 flexis and one box in the middle and no backbox. ONLY 67K MILEAGE!! Unless engine been chnaged car runs fine though.

[@AntonLippek]

@@zZZSPARKZZz did you get the injector seals reseated when replaced? Carbon deposits build up below the seals and the bloc can be worn away and can cause this. Reseating requires careful drilling. If remapped for a bigger turbo you will need fresh map for new turbo as less fuel required. I'd start with a remap

[@zZZSPARKZZz]

the injectors had no carbon surprisingly very clean? Just surprised that tappets are noisy i can send you a video so you can see. The car is costing me too much and i am worried.

[@AntonLippek]

@@zZZSPARKZZz noise tappets are often confused with other sounds. One cause for noise tappets is low oil pressure. Have you done oil and filter change recently?

[@bigmanminivan840]

I wish I could see what was going on sort it out please

[@ryanh3285]

Great video where do you get the hand primer? My old car had one built in this is a bit of a pain but it is what it is.

[@AntonLippek]

Ryan H pretty much every auto hardware store will stock the primer bulbs

[@ryanh3285]

Ok Thanks ill give it a go I think its worth changing every 20000 miles personally.

[@jonathanwagner8536]

Hey Mate, where did you buy that one way pump?

[@AntonLippek]

Euro car parts in the UK, though most car motor spares stores have them

[@vapester2528]

Whats the inner mm of the pipe you are using?

[@AntonLippek]

I used 10mm hose/pipe but other priming bulbs may need different sized hose

[@vapester2528]

Thx :), I have 1.6 TDCi with same filter so need to buy the right Bulb and pipe for bleeding.

[@AntonLippek]

the bulbs are made so the fit a wide range of pipes with a tappered nozzle so best to get the pipe first and make sure it fits onto the filter side first, that's why I made the little adaptor with the dust cap from the filter, you can pick up the bulb in most auto parts shops so can get at the same time :)

[@stevepowell8923]

I watched this video (and several more), read my Haynes manual, thought 'THIS IS SIMPLE!!'.... How wrong I was. Pipes plugged & nipped to prevent drawback of fuel... Primed filter with no bubbles... Unplugged pipes and topped up... Quickly reattached pipes to ensure minimal fuel loss... Turned key to position 2 (5 times, ignition on 6th) and it fired and ran for about 3 seconds before stalling. Now it won't restart despite going through the motions about 10 times.. Well frustrated!!.. Must now have an air-lock in system.. I know I am not alone... Any ideas how to get rid of air lock as my mate who fixes wagons just laughed and said 'They are a c*** to sort out' but unfortunately he couldn't help with all his technical jargon and doesn't carry his workplace workshop around with him... Wife now not happy as it's her car!!! (That's the worst bit)...

[@AntonLippek]

You could use a syringe or carefully add the fuel into the filter outlet pipe, adding by the drop or bit by bit. Any air will bubble out of the pipe, the level will drop as it comes out so keep adding slow till the pipe is full, then connect to the primed fuel filter. Once the engine is running, keep it running and give the car a good run. One thing to note, nipping the pipes as you mentioned may have put a small hole in them so check for any leaks once you get it running, that could be the reason for air getting in

[@stevepowell8923]

Many thanks for the advice. I managed to sort it by filling a bottle with fuel then using the purge pump to pump the fuel from the bottle in to the inlet port on the filter (keeping the outlet pipe fitted to the filter). As it was filling and I got a back pressure on the hand pump, my mate turned the engine over and it fired up whilst still pumping. As it was still running I quickly fitted the inlet pipe then gave the car a good rev before taking it out on a run.... So far so good :)

[@AntonLippek]

@@stevepowell8923 great, hopefully that's all good now then, great engine's but why they did away with a inline primer like the older cars had I don't know.. Service plan profits I guess

[@sjfortune]

​@@stevepowell8923haha good fix 😂 about to do mine so nice to know you got it in the end.