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Old 03-20-2012, 12:41 AM   #1
NelsonSprinter
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Default Found a Fix to Fuel Filter leaks '02-03 T1N

My OM612 '02 has had a fuel filter issue with leaks that I couldn't resolve for 6 months 'til now.
1.Tried new filters, still sucked air, yes I purged everytime, would run, but not next day every time, and stalled at worst times.

2.tried new O-rings, new temp valve, same leak
3.tied new fuel lines, still had a little air in fuel line after days of running, hard starts
4.tried different brands of filters, Hengst, WIX, Daimler C etc, all leaked, got frustrating
5. tried new drain valve screw, nope, new water sensor, nope

THE FIX I Installed a fuel filter design from Europe for European Sprinters without the water sensor on the bottom and no water drain valve. No Leaks, no air, no stalls, starts everytime !
I never saw a great engineering design in a fuel filter with 7 connections to possibly leak, it should have an in and an out. The fix has 5 connections that still could leak, but fixed my van
The filter is only available in North America on-line, mine came from eBay for $30.
Since my fuel filter has never had water in it when drained, and the WIF light never came on, I think I will be fine without a drain (LEAK) hole. The Top connections are a perfect fit.

Part Numbers :MB # 6110920201, or 6110920601, or 6110900852, or 6120920001,
Fram P9436
Mahle KL100/1 or /2
Bosch 0450905930
MANN WK842-13 OR -17
Hengst H70WK11 or H70WK18
WIX WF8239
Baldwin BF7756
Attached Images
File Type: jpg fuelfilt.jpg (141.5 KB, 1255 views)
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Previous owner of '02 FL 2500 140WB Cargo door windows, 15" Alloys, LT235/75R15-E Nokian Rotiivas, Nokian Hakka C studded winters, Curt 4 hitch, 3.72 rear with 30MPG Cdn GDE ECO Tuned. . .
I am NOT a MECHANIC, I just play one online.

'02-'03 Fuel filter leak fix http://sprinter-source.com/forum/sho...ix+fuel+filter
15" tire options http://sprinter-source.com/forum/sho...t=tire+options

Last edited by NelsonSprinter; 03-20-2012 at 12:46 AM.
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Old 03-20-2012, 01:37 AM   #2
johnschroader
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Default Re: Found a Fix to Fuel Filter leaks '02-03 T1N

For what it's worth, I have installed two inline filters ahead of my factory filter ( a 10 micron and a 5 micron). Hopefully will not have to change the factory filter again. It does seem to me to be way harder than necessary. Still, it's better than the filter on my old 7.3 Powerstroke (E 350). Now THAT was a real pain.
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Old 03-20-2012, 02:40 AM   #3
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Default Re: Found a Fix to Fuel Filter leaks '02-03 T1N

Even with about a half dozen changes under my belt, sometimes I have to re-do the connections several times to get them to stop leaking. I've cobbed together multiple o-rings and rubber washers to make the crappy Hastings filters work, Hengst don't seem to be such a problem. The water sensor design on the OM612 motor fuel filters really sucks. This info that I can put one in that doesn't have that sensor hole in the bottom is great news. Now to figure out how to make the sensor think everything is fine...
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Old 03-20-2012, 02:46 AM   #4
sterling
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Default Re: Found a Fix to Fuel Filter leaks '02-03 T1N

Quote:
Originally Posted by NelsonSprinter View Post
My OM612 '02 has had a fuel filter issue with leaks that I couldn't resolve for 6 months 'til now.
1.Tried new filters, still sucked air, yes I purged everytime, would run, but not next day every time, and stalled at worst times.

2.tried new O-rings, new temp valve, same leak
3.tied new fuel lines, still had a little air in fuel line after days of running, hard starts
4.tried different brands of filters, Hengst, WIX, Daimler C etc, all leaked, got frustrating
5. tried new drain valve screw, nope, new water sensor, nope

THE FIX I Installed a fuel filter design from Europe for European Sprinters without the water sensor on the bottom and no water drain valve. No Leaks, no air, no stalls, starts everytime !
I never saw a great engineering design in a fuel filter with 7 connections to possibly leak, it should have an in and an out. The fix has 5 connections that still could leak, but fixed my van
The filter is only available in North America on-line, mine came from eBay for $30.
Since my fuel filter has never had water in it when drained, and the WIF light never came on, I think I will be fine without a drain (LEAK) hole. The Top connections are a perfect fit.

Part Numbers :MB # 6110920201, or 6110920601, or 6110900852, or 6120920001,
Fram P9436
Mahle KL100/1 or /2
Bosch 0450905930
MANN WK842-13 OR -17
Hengst H70WK11 or H70WK18
WIX WF8239
Baldwin BF7756

May I please ask how I can order one for my 2003 3500 T1N?
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Old 03-20-2012, 03:14 AM   #5
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Default Re: Found a Fix to Fuel Filter leaks '02-03 T1N

Hi Nelson Sprinter,

The problem with the leaks that you have been having is probably because the wrong type of hose clamp is used as shown in your picture. They have a tendency to allow air to be sucked into the fuel line as they do not apply equal tension to the complete circumference of the hose pipe. It is for this reason that the original type of hose clamps should be used. They are called Cobra clamps, As shown in this link. http://normapacific.com/prod_hose_cl...ose_clips.html
Irrigation suppliers usually have them in various sizes. They can also be reused... No need to use new ones each time you change the filter. I have seen Sprinters stuck on mountain passes which have had exactly this problem.

Cheers

Ross
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Old 03-20-2012, 05:31 AM   #6
NelsonSprinter
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Default Re: Found a Fix to Fuel Filter leaks '02-03 T1N

Quote:
Originally Posted by surlyoldbill View Post
This info that I can put one in that doesn't have that sensor hole in the bottom is great news. Now to figure out how to make the sensor think everything is fine...
My sensor is still hooked up to the connection, and since no water is connecting the electrodes, it thinks everything is normal.

EBAY is only place that I have found them, but I'm sure an internet search will find Auto parts suppliers in Europe who will sell online and ship to you too.

Thanks for the tip 'oldfartt' but since it doesn't leak or such air I'll leave it alone for now.
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Previous owner of '02 FL 2500 140WB Cargo door windows, 15" Alloys, LT235/75R15-E Nokian Rotiivas, Nokian Hakka C studded winters, Curt 4 hitch, 3.72 rear with 30MPG Cdn GDE ECO Tuned. . .
I am NOT a MECHANIC, I just play one online.

'02-'03 Fuel filter leak fix http://sprinter-source.com/forum/sho...ix+fuel+filter
15" tire options http://sprinter-source.com/forum/sho...t=tire+options
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Old 03-20-2012, 03:09 PM   #7
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Default Re: Found a Fix to Fuel Filter leaks '02-03 T1N

So far the only issue I've had with my OEM filter setup is getting the connections apart and back together again. Everything is so tight (even the seals on the electrical connector) that I have to use WD40 to provide the necessary lubrication.
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Old 03-21-2012, 02:11 AM   #8
NelsonSprinter
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Default Re: Found a Fix to Fuel Filter leaks '02-03 T1N

I could not find the filtering micron specs on these, but the standard policy is to meet OEM specs FWIW. It's probable Mann's is better.
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File Type: jpg $(KGrHqR,!k4E4llRB(odBOS!CDrfWQ~~0_12[1].jpg (25.3 KB, 1009 views)
__________________
Previous owner of '02 FL 2500 140WB Cargo door windows, 15" Alloys, LT235/75R15-E Nokian Rotiivas, Nokian Hakka C studded winters, Curt 4 hitch, 3.72 rear with 30MPG Cdn GDE ECO Tuned. . .
I am NOT a MECHANIC, I just play one online.

'02-'03 Fuel filter leak fix http://sprinter-source.com/forum/sho...ix+fuel+filter
15" tire options http://sprinter-source.com/forum/sho...t=tire+options
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Old 03-21-2012, 04:50 AM   #9
NelsonSprinter
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Default Re: Found a Fix to Fuel Filter leaks '02-03 T1N

Quote:
Originally Posted by sterling View Post
May I please ask how I can order one for my 2003 3500 T1N?
You can order online from Rockauto.com in the USofA
http://www.rockauto.com/dbphp/prt,39,WF8239
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Previous owner of '02 FL 2500 140WB Cargo door windows, 15" Alloys, LT235/75R15-E Nokian Rotiivas, Nokian Hakka C studded winters, Curt 4 hitch, 3.72 rear with 30MPG Cdn GDE ECO Tuned. . .
I am NOT a MECHANIC, I just play one online.

'02-'03 Fuel filter leak fix http://sprinter-source.com/forum/sho...ix+fuel+filter
15" tire options http://sprinter-source.com/forum/sho...t=tire+options
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Old 03-22-2012, 09:15 AM   #10
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Default Re: Found a Fix to Fuel Filter leaks '02-03 T1N

May I add to this post please . I use the following for ALL fuel line fittings ... double ear O-clips , when you crimp them closed , they tighten equally all round the pipe
I have yet to have one leak wither under vacuum or under pressure . I use them on compressed air , oxygen & fuel gas pipework as well . They are way better than jubilee clips ( as we know them in the UK ) . They are a one use item , but come in mild or stainless steel so you can make your engine bay look nice & shiny if you wish .
The O clips have cured many leaking diesel fuel systems , just because they clamp equally all the way round . I have also found using them that you cannot overtighten them , thereby distorting the fitting & pipework , SO you eliminate any possible leaks , hope it helps
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