Leaking fuel filter housing.

Hi Paul,

When Spike mentioned you in relation to printing out some replacement screws, I thought that it wouldn't really be a go-er as I'd imagine the printing substrate is even more fragile and susceptible to fuel contamination than the original plastic. However, if you could knock up some ally or brass screws, these would doubtless be an excellent and long-term solution.

I've included 2 photos below showing the screw in question (it's part 1 from the parts drawing). It's basically a coarse thread M8 bolt with a large flange and 2 x O rings on it, plus a hole through it for pressure relief (I think). I'm going to get a new housing in the new year as I want to replace my filter when I'm under Tank re-doing all the heat shield fixings, so we can sort something out then I daresay and we're not a million miles apart - St Annes and Warrington.

Picture008.jpg~original.jpeg

FuelFilterAssembly.jpg~original.jpeg
 
Skipton01 said:
Hi Paul,

When Spike mentioned you in relation to printing out some replacement screws, I thought that it wouldn't really be a go-er as I'd imagine the printing substrate is even more fragile and susceptible to fuel contamination than the original plastic. However, if you could knock up some ally or brass screws, these would doubtless be an excellent and long-term solution.

I've included 2 photos below showing the screw in question (it's part 1 from the parts drawing). It's basically a coarse thread M8 bolt with a large flange and 2 x O rings on it, plus a hole through it for pressure relief (I think). I'm going to get a new housing in the new year as I want to replace my filter when I'm under Tank re-doing all the heat shield fixings, so we can sort something out then I daresay and we're not a million miles apart - St Annes and Warrington.

View attachment 32688

View attachment 32689
Click to expand...

Do you happen to know if it is a standard M8 course thread i.e. 1.25mm pitch ???

If it is then I'm sure that I can machine these out of aluminium bar (cheapest) or brass bar (more expensive)
The diameter (cross section) and the dimensions of the O rings would be helpful especially if these can be obtained from a new set of O rings (so there is no chance of then stretching after use)

Difficult to see from the photo but I would think about £12 to £15 with new O rings in Aluminium likely about £5 more in Brass

If you can loan me the part and an housing so I can ensure that the finished metal one works OK then that would be great and I'm sure appreciated by the community as I have seen over the last 18 months lots of people asking for these and getting a £75 bill for a new fuel filter housing ( :mad: )

Cheers,
 
I don't know off the top of my head what the pitch is, but we'll meet up in the new year and get this sorted. My main thoughts on using brass were to do with thermal expansion and the threads still making good contact with the plastic housing body.

I'll buy a housing kit which will come with new O rings (as pictured) and get it to you for appraisal. Will you be able to make the recessed hex head on the part - that looks the most challenging bit to me?
 
I can't see the recess that you are describing, do you a better picture of the actual screw ?

Does it need to be recessed or can it be an external Hex, I assume it is only there to tighten the screw ?

Cheers,
 
depronman said:
I can't see the recess that you are describing, do you a better picture of the actual screw ?

Does it need to be recessed or can it be an external Hex, I assume it is only there to tighten the screw ?

Cheers,
Click to expand...

Take a look at the following thread - some great photos on there showing the little screw and how the hex head is recessed.

http://www.a2oc.net/forum/showthread.php?20328-fuel-filter-1-4-tdi-2004

It is there purely to tighten the screw and I suppose it could be external, depending on the heat shield positioning. It could also be replaced by a recessed hex head - so you'd undo with an allen key.
 
What about making the outer diameter of the screw a little less than the 27mm A/F of the nut molded into the filer housing cover, make it a little thicker say about 6mm and knurl it. This would then allow grip to tighten the screw and undo the screw and the socket to be fitted over the screw to undo the housing cover to remove the filter element

Difficult to say without having the housing in my hands
Assuming the housing is made from ABS then the expansion of ABS and Aluminium as very similar, brass no so similar, therefore Aluminium is the way to go
I could get them anodized, but that would add to the cost, I think some etch primer and a coat of paint will work well
Or I can get some alocrom from work (used to touch up repairs on bear aluminium prior to paint touch up

Cheers,
 
Good thinking - or even make it slightly larger than the 27mm nut and still knurled. This would then mean the housing cap nut is protected from damage and you'd have to remove the drain screw before undoing the main cap.

Either way would work - and with no hex head on it, you could only ever tighten it finger tight, which isn't a bad thing.
 
Skipton01 said:
Good thinking - or even make it slightly larger than the 27mm nut and still knurled. This would then mean the housing cap nut is protected from damage and you'd have to remove the drain screw before undoing the main cap.

Either way would work - and with no hex head on it, you could only ever tighten it finger tight, which isn't a bad thing.
Click to expand...

My thinking exactly (re over tightening) we are on the same wave length :)

Get me either the new or the old housing and I'm sure that I can work out something that will work as per the original plastic screw, but with more durability (AKA the refanufactured door check straps)

Audi did a great job on the A2, but designs can always be improved upon even if only to remove the built in obsolescence

Cheers,
 
how did you guys get on with the modded nut? is this still a work in progress because i would be interested in buying one like many others :)
 
Mr Angry said:
how did you guys get on with the modded nut? is this still a work in progress because i would be interested in buying one like many others :)
Click to expand...

Paul depronman has completed the replacement screw. Hats off to him for taking on this for the good of tdi owners.

R
 
Cammy, they are £23ea plus £3 delivery, if you want check straps then delivery is free as the screw will go with the check strap

Cheers,
Paul
 
Hi there... I have been reading the thread about replacement screws on the plastic fuel filters.. I may need one of these... how do I go about buying one? Many thanks
Mo ,London A2 2005
 
You must log in or register to reply here.
Back
Top