Replacing The Fuel Filter In A 1997 Fzj80: Step-By-Step Guide

Changing the fuel filter on a 1997 FZJ80 is a challenging task, but with the right tools and preparation, it can be accomplished. The fuel filter is located under the intake manifold, which makes it difficult to access. However, with the help of extensions, wrenches, and a ratchet, it is possible to reach and loosen the bolts holding the fuel filter in place. It is important to relieve the pressure in the fuel system before beginning the replacement process. Additionally, there are two fuel filters in the FZJ80: one in the tank and one under the manifold. The tank filter is easier to replace, while the one under the manifold is more challenging. When replacing the fuel filter, it is recommended to cut a notch into the new filter's tab to make future installations easier. It is also important to be careful not to break the #2 knock sensor, which is located near the fuel filter.

The fuel filter is located under the intake manifold

The fuel filter on a 1997 FZJ80 is located under the intake manifold. It is a tricky spot to reach, but it is possible to replace the filter yourself.

To access the fuel filter, you will need to work from underneath the vehicle. You may need to remove the driver's side front wheel and inner mud guards to gain better access. It is also recommended to place the vehicle on jack stands to raise it and give you more room to work.

Before starting, relieve the pressure in the fuel system by opening the fuel filler cap. You should also disconnect the fuel pump. When removing the fuel filter, it is important to loosen the banjo bolts on each end of the filter before loosening the bolts that hold the filter to the intake manifold. This will help prevent fuel spillage.

When reinstalling the new fuel filter, some people find it helpful to cut a notch into the mounting tab closest to the head for easier installation. You will also need to use new crush washers with the banjo bolts. Make sure to tighten the banjo bolts to 29 Nm (22 lb-ft) and the filter mounting bolts to 21 Nm (15 lb-ft).

This is a challenging task, and you may require some contortionist skills to reach the fuel filter. Having an extra set of hands to help can make the process easier.

You need to relieve the fuel pressure

To relieve the fuel pressure, you can start by removing the gas cap. This will remove the pressure in the tank. You can also disconnect the fuel pump connector and try to start the engine, or simply pull the FP relay or circuit-opening relay to let the engine stall. This will minimize the pressure in the fuel line.

• Before loosening the mounting bolts on the filter, loosen the union bolts through the banjo fittings.
• Be careful not to bend the ridged fuel line at the rear of the fuel filter, as this will make lining up the union bolt difficult.
• If you don't have long, skinny arms, consider getting extra crush washers, as they tend to drop and are hard to retrieve.
• Removing the front tire and inner mud guards can provide better access to the fuel filter.
• It is recommended to change the fuel filter every 18,000 to 30,000 miles, especially if you are using fuel from questionable sources or older gas stations.

You will need a 7/8 wrench and 17mm for one side and a 3/4 wrench and 17mm for the other side

Changing the fuel filter on a 1997 FZJ80 can be a challenging task, but with the right tools and some persistence, it can be accomplished. One of the key steps in this process is safely removing and replacing the fuel filter, and the tools you will need for this are a 7/8 wrench and a 17mm wrench for one side, and a 3/4 wrench and a 17mm wrench for the other side.

The 7/8-inch wrench, or a 7/8 combination wrench, as it is sometimes called, is a standard size in the American wrench sizing system, where sizes range from 5/8 to 1/8. This particular wrench is used to turn fasteners, such as bolts and nuts, that are the corresponding size. The 17mm wrench, on the other hand, is from the metric system, which uses millimetres as its unit of measurement.

When it comes to the 3/4-inch wrench, this is another standard size in the American sizing system, and it is used for fasteners that are larger than 1/2-inch but smaller than a 5/8-inch. As for the 17mm wrench, it is a useful tool to have when working on cars, as it can be used on both SAE (Standard American) and metric nuts and bolts.

By using these wrenches together, you will be able to loosen and tighten the fittings on the fuel filter of your 1997 FZJ80 with greater ease. It is important to remember to use both wrenches at the same time for the easiest experience when working on these fittings. Additionally, it is recommended to relieve the pressure in the fuel system before beginning any work and to be prepared for some fuel spillage.

You will need to remove the gas cap to avoid spillage

When changing the fuel filter on a 1997 FZJ80, you will need to remove the gas cap to avoid spillage. This is because the fuel system needs to be depressurised before you start. Removing the gas cap is one of the steps to do this, along with loosening the cap until you hear the pressure escaping, and removing the fuel pump fuse or relay.

It is important to avoid fuel spillage for safety reasons, as well as to avoid the mess it can cause. The fuel system is pressurised, and removing the gas cap relieves this pressure. This means that when you disconnect the fuel lines, there will be less fuel that sprays out or dribbles out.

Even with the gas cap removed, you should still expect some fuel to come out of the lines when you disconnect them. It is a good idea to have some rags or old towels ready to catch this fuel, and to plug the open fuel line with a rag to avoid further spillage. You should also be sure to work in a well-ventilated area so that gas fumes can escape.

You will need to remove the oil filter to access the intake manifold

To change the fuel filter on a 1997 FZJ80, you will need to remove the oil filter to access the intake manifold. This is because the fuel filter is tucked under the intake manifold on the driver's side, making it a bit tricky to reach.

• Park your vehicle on a level surface and engage the parking brake.
• Relieve the fuel system pressure by opening the fuel filler cap.
• Locate the fuel filter under the intake manifold. You may need to look from the underside of the manifold or from the left front wheel well.
• Before removing the fuel filter, loosen the fuel line banjo bolts. You can access the front banjo bolt from above the front fender, and the rear banjo bolt through the left front wheel well.
• Remove the oil filter to provide better access to the intake manifold.
• With the oil filter out of the way, you can now reach the fuel filter more easily. Remove the bolts holding the fuel filter to the intake manifold.
• Carefully remove the fuel filter, being mindful of any fuel spillage.
• Install the new fuel filter, ensuring that you grease the new banjo bolt washers to hold them in place.
• Tighten the fuel line banjo bolts and the mounting bolts on the new fuel filter.
• Reinstall the oil filter.
• Close the fuel filler cap to complete the process.

By following these steps, you will be able to successfully change the fuel filter on your 1997 FZJ80, ensuring that you have better access by removing the oil filter to access the intake manifold.

Frequently asked questions