Fiat Ducato Fuel Filter change. WITH NO LEAKS

Having learnt the hard way. John shares how to change the filter element in a Fiat Ducato 2.3 engine without creating future fuel leaks. In this case he is doing it on his Rapido 9090F 'A' Class motorhome called 'Ruby'
Here are some links to items you will find useful if you want to complete the same task for yourself
Fuel filter tightening tool
amzn.to/3e6zRfE
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[@martinsmith4943]

Very useful video, thanks. John I believe that those yellow marks are from the UFI factory, implying that the filter unit you took out had been correctly assembled and torqued - yet it still failed. I am on my third housing in 11,000 miles. The first leaked after Covid lay-up, the second poured out fuel when I restarted the engine hot - but the leak would stop soon after. I suspect that the housing material and seal are not up to the temperature, pressure and ageing required by the environment they are in. Maybe that's why later Ducato's are all fitted with a metal housing, not a plastic one.

[@ToTheGarage]

Yes although its possible to get the plastic one right, A metal housing will have far less if any issues in this regard.

[@davidhitchen7122]

Just changed the whole housing on mine using your vid, 3 different garages couldn't stop it leaking. Thanks for the vid, I'd have struggled with those connections otherwise 👍👍👍

[@ToTheGarage]

Glad it helped David

[@wilvandendoel4289]

You don’t have to remove the headlight from a standard Ducato, just move the filter body below the brake lines and its out.

[@ToTheGarage]

Thanks Wil

[@UdoIBress]

well done john. Diesel is dirty. you can see it on the open filter. Thanks for showing us. Regards Udo.😻 By the way, "Der CATZE" passed its main test. New coupling rods, shock absorbers, new exhaust and new brakes. Universal joint new and stabilizer bushings new. It was a lot of work. 😹

[@ToTheGarage]

Thanks Udo👍 Looks like Der CATZE has had a lot of new presents👍

[@wilvandendoel6782]

Thanks for the tip, I ordered the tool, didnot know this existed.

[@CerberusVelvet]

Can you connect a hose to the leak down valve first and open it to drain the filter so you don’t make as much mess disconnecting the fuel lines?

[@ToTheGarage]

Yes you could and thats a very good Tip. I should have done that

[@CerberusVelvet]

@@ToTheGarage I will do that then :D Cheers, great video.

[@garyvanremortel5218]

That's a great filter arrangement. The canister is very much like the gascolator water separator used in small aircraft, except we have successively finer mesh screens from fuel tank to carb instead of filter media.

[@ToTheGarage]

Does that mean they are 'washable' and never need replacing Gary?

[@garyvanremortel5218]

@@ToTheGarage Correct. You back-flush them during your mandated annual inspection. But in a practical sense they may ultimately clog with small particles that restrict flow, requiring their replacement after a very long life.

[@peskyparttimers8239]

Thanks for this, just done mine and it was found to be only hand tight. Hoping this will have cured this slight misfire I have when under load.

[@ToTheGarage]

Lets hope so. Let us know

[@harrys40]

Yea thanks for video have ordered tool 👍

[@michaelfraser5723]

CLEAR EXPLANATION, THANKS

[@ToTheGarage]

You are welcome!

[@neillfoster3716]

Nice video John , but there is a fundamental design flaw in the filter housing The rubber seal is square in profile and there is no support to stop the seal migrating outwards You may have no leaks now but over time and temperature changes the seal will pop out eventually The first notice you will get is fuel pouring out when you stop , or low fuel after you have coated the road behind you I will wager you about 10K miles and you will be stranded It’s well documented, google Fiat Ducato fuel filter problems It’s dangerous Best you carry a spare , mine stuck me on the A14 for 8 hours 😩

[@ToTheGarage]

Hi Neill Thanks for the intel. The new filter came with a conventional round section O ring. Im pretty sure the one I removed was round too🤔 I have still got the old one on my shelf so can check. However as stated in the video my filter housing is an aftermarket one, so potentially the design has moved on?

[@XR400vsGS12]

I had problem with filter housing. It was broken the hosing. Maybe due to fuel pressure, it was expanding with pressure, than material was tired and started leaking with strong pressure on the highway. Not related to filter cartridge replacement. Nasty, very nasty problem. Btw John, did the yellow marks coincide after tightening 30nm or you run a centimeter more ?

[@davidhitchen7122]

This is so true!

[@kampenheimer]

Just about to do this job. You are correct that the seal has a square profile. John’s one in the video also has it. Freeze the video at 11:53 and you’ll see it. I have an alco filter and I’ve just checked the rubber seal. What’s interesting and not mentioned is that the seal’s square profile also has 6 grooves, which I am assuming are for correct alignment when installing the seal. The Laser tool also has these 6 grooves. I haven’t done the job yet, but I’ll bet the housing has them too. This would imply that correct alignment and positioning of the rubber seal is crucial to avoid potential leaks. The seal grooves can also be seen at 11:53.

[@avianofreeman6122]

Roba da pazzi!!! Per cambiare un filtro gasolio bisogna laurearsi in meccanica!!🤯

[@ToTheGarage]

🤣🤣

[@lindsayperrin]

When you re-tightened the screw top, was the 'yellow mark' more or less than 30nm?

[@AndreasEUR]

Clicked twice though

[@phillipbrion6574]

well done most helpful thanks !! Phil.

[@ToTheGarage]

You're welcome Philip👍

[@MecaEvolution]

My question is: it not possible to drain it when it is inside the car?

[@graemeralph2225]

Could you add a link to the filter you bought?

[@offshoretomorrow3346]

Cannot budge that top fuel pipe!

[@johnclarke6542]

Never used any fancy tools you can remove it from the bracket just slides up out the bracket, put the filter in a workmate loosely clamp it, get yourself a block of wood and hammer tap the ring around keep it simple sell you tools you don't need, it's the same filter element on the early 244 Ducato's, vauxhall corsa diesel, I can only think people are crushing the housing or overtighten the ring or not lubricating the o ring, MMM magazine has made a big deal out of this it's not rocket science

[@ToTheGarage]

I agree its the inadvertent Crushing of the ring when tightened with grips or a pair of Stilsons that is causing most of the leaks. So your tap it round technique is far more appropriate than any other in the absence of a full form tool👍

[@rogierjansen]

For you it isn’t, for most of the garages it is. Mine was leaking after a big service with a filter replacement and the things was tightened way too hard. Apparently it’s hard to find decent repair shops nowadays that know how to fix things rather than touching a keyboard to repair stuff.

[@lucamatteobarbieri2493]

gloves

[@ToTheGarage]

Fair comment👍