Pelican Fuel Filter doesn't fit

[70S Targa Guy]

I purchased a Mahle KL 21 Fuel filter for my 3.2 engine from our host and my old banjo fitting from my old filter (KL 21 filter superseded old filter part number) does not fit. See pic below. The fitting on the left side where the plastic cap is still in place is identical to the old filter fitting and will fit. However, the fitting on the right does not fit. My old banjo bolt pictured on the right is too skinny and will not screw into the brass fitting that was attached to filter when I purchased it. My old filter did not have that brass fitting on the right side. On the old filter the banjo bolt pictured screwed into the silver bolt on the filter that is actually part of the filter. I tried to remove the brass fitting but it did not loosen after great force was put on it so I stopped trying to force it off for fear I might damage it or break it off.

My question is about that brass fitting. Is the brass fitting threaded and screwed into the filter or is it actually welded and part of the filter itself body itself and does not come off? I would think if it could be removed my old banjo bolt will fit in those threads on the silver part of the filter just like my old filter. If it doesn't come off I guess I would have to purchase a larger threaded banjo bolt that will fit in the new filter's brass fitting threads. Any advise is appreciated. Thanks.

[john walker's workshop]

you must have a 3.2 in something other than a carrera body, as carreras don't use a banjo bolt. the filter fitting is screwed in and loctited. hard to remove without screwing up the aluminum threads, but i've done it. two wrenches in a V position and squeeze hard. then clean the threads of loctite crusties. what was the old filter number?

[70S Targa Guy]

Thanks for the reply John Walkers Workshop. You are correct, it is a 3.2 in a 1970 S. The very old filter (perhaps 22 years old) I just removed in an attempt to correct a very rough running car is 928.110.253.00. Please check out my previous thread regarding my fuel filter setup found here: 1986 3.2 Fuel Filter Help

As you can see in that thread, my banjo bolt screwed into the old filter's threads labeled #2. Am I correct in assuming that the hole and threads located in the new filter (after I wrestle off the brass fitting as you described) will be the same size as # 2 in old filter? Thanks again.

[DUK]

I have to do this with my setup also. I just clamp a wrench in my vise to hold the filter and then turn the fitting out. It has some kind of loctite or sealant on it, I did heat the first one a little with a butane torch. Of course that was before I had put any gas in it.

[john walker's workshop]

i guess you'll have to find that out. there's also a KL22 filter that looks exactly the same, same fittings, but there must be someting about it that's different, hence the different number. i never figured it out. maybe one or the other has different threads in the aluminum part. there's also a large body turbo filter bosch # 0 450 905 281 that has a smaller upper fitting, external threads, so maybe that one will fit.

[70S Targa Guy]

Thanks for your help fellas. I will report this weekend after I attempt to remove the fitting and attach the filter. Hey Duke, does your fitting and fuel hose on your '75 3.2 fuel filter look like mine below?

[DUK]

No, I'm using the tapered style fittings on both ends, with the metric fitting out of the filter used on both ends. I'm not using the banjo setup like yours.

[70S Targa Guy]

A follow up report on retrofitting my fuel filter:

Well, I had to get my oil changed in my daily driver so I brought along my new fuel filter with me. The mechanic easily removed the brass fitting on the inlet (right) side of filter pictured above with his air tools. It took him 3 seconds. I cleaned out the threads and attached the tapered end to the part of filter that feeds the engine. Then I attached my banjo bolt to the modified part of filter. I tightened both fittings EXTREMELY tight. I hooked up battery and turned ignition just enough to get the fuel pump going and see if I had any leaks. I run back to engine and fuel is spraying all over the place. After I turn off ignition key and disconnect battery I go back and the system is still under pressure and moderately spraying fuel from the banjo connection. Since my car is on jacks and in an old wooden barn with several other cars, the last thing I need is fuel all over the place. I took off fuel filter and soaked up all the gas on engine sheet metal and plugged up the fuel hose with the banjo connection.

The only thing I can think of that I did wrong was when I attached the banjo bolt to fuel pump I placed one crush washer on each side of the banjo connection. That is, looking at the first picture I placed a crush washer on the banjo between banjo bolt #1 AND bolt # 2. Looking at the same picture it is tough to tell but it looks like BOTH crush washers are on the bolt at #1. That may be the problem. But now that I have the fuel pump out of the car when I hand tighten the banjo bolt in the new fuel filter there is a tiny bit of play between the bolt and the threads of the fuel filter; I can actually wiggle the bolt very very slightly while it is fully threaded in???? Could this be the culprit and source of leak? Even though when I attached the fuel filter in the car where it appeared the banjo bolt did tighten very very snug and extremely well, maybe pressurized fuel found its way out through this tiny bit of play in the threads. Any ideas?

I have gone this far so I will go back to the car, take it off the jacks and roll it to the barn door (err on the side of caution just in case of a mishap next time) and try reattaching fuel filter with both crush washers between banjo bolt and #1 of fuel filter. If it still leaks, I may have to get some type of new high pressure fuel hose and fitting.

[DUK]

The washers go one on each side of the banjo fitting. Are they new washers? They must be new and flat. I've even had to lap them on a sheet of 1200 paper on a sheet of glass.

Also make sure your washer sits inside of the recess on the filter.

[70S Targa Guy]

Originally Posted by Duke Zink

The washers go one on each side of the banjo fitting. Are they new washers? They must be new and flat. I've even had to lap them on a sheet of 1200 paper on a sheet of glass.

Also make sure your washer sits inside of the recess on the filter.

They are original old (1986) washers that I appear to be flat. What do you mean by :I've even had to lap them on a sheet of 1200 paper on a sheet of glass?

[DUK]

Glue a piece of 1200 grit sandpaper to a sheet of glass and put a spray a little penatrating oil on it. Then place the washers flat side down and using a figure 8 pattern, sand a little off of them to make sure they are flat.

I would look into the recess on the filter, my original washers were a little big to fit in it and so held the washer off the seating area.

I would suggest finding some new alum. or copper washers. Check the local hardware store, I've found them there sometimes. If not try a racing shop around you or Pelican surely has them.

[70S Targa Guy]

Thanks for all your help Duke. It seems wise for me to get two brand new crush washers for the fuel filter install. I will include them in my order from our host (even though I don't see them listed anywhere on the site). This banjo setup on one end of my fuel filter is definitely not as good of a design as the tapered connection on the other end. I can now see why the manufacturer of the fuel filter retrofitted a tapered fitting on the end I am trying to fit my banjo bolt. I will have to wait now until I receive the new washers. Thanks again for sharing your experience in dealing with this setup.

[DUK]

I was just looking over your setup again and noticed the hose clamp on the line to the banjo fitting. I would look into eliminating that as it may be what's leaking insted of the washers at the banjo. Maybe replace that hose with something like I've got. Any local hydraulic hose maker should be able to figure something for you.