Replacing Donaldson Fuel Filters: A Step-By-Step Guide

Donaldson offers a wide range of fuel filters for popular on- and off-road engines, including Cummins® X15 / ISX, Cummins® QSK, and Detroit™ DD13® / DD15® / DD16® engines. Their fuel filters are designed to prevent premature injector and pump wear by delivering clean fuel to engines. Donaldson provides both standard and premium quality filters that meet or exceed application requirements. The company also offers replacement filters for popular fuel systems and various filter options, such as spin-ons, fuel-filter-water separators, and cartridges. When changing a Donaldson fuel filter, it is important to follow the proper steps, including unscrewing and removing the old filter, disposing of it according to local regulations, and ensuring proper tightening of the new filter.

Donaldson filter removal

Spin-On Fuel Filter Water Separator (FFWS):

• Disconnect the Water-In-Fuel (WIF) sensor if your vehicle has one. It's important to do this before proceeding.
• Unscrew and remove the old filter and gasket. Be sure to properly dispose of the used filter according to local regulations.
• Wipe the filter head with a clean cloth to ensure no dirt or debris is left behind.
• Do not pre-fill with fuel unless otherwise specified by the manufacturer.
• Apply a thin film of clean motor oil to the gasket. This will help create a tight seal.
• Align the threads and spin the new filter on until gasket contact is made.
• Follow the icons on the filter to tighten it to the appropriate torque specification.
• Reconnect the Water-In-Fuel (WIF) sensor if you disconnected it earlier.
• Prime the fuel system per the manufacturer's instructions.
• Start the engine and carefully check for any leaks.

Davco®-Type Cartridge:

• Remove the vent cap and seal.
• Remove the collar, cover, and seal.
• Take out the cartridge and old grommet. Dispose of the used cartridge according to local regulations.
• Clean the collar, cover, and threads to ensure no debris is left behind.
• Check the new grommet and install the new cartridge.
• Install the seal, cover, and hand-tighten the collar.
• Fill the cover with fuel.
• Fit the new vent seal and cap, then hand-tighten.
• Start the engine and warm it up. Increase the RPM for one minute.
• Slowly open the vent cap until the fuel rises 25mm or 1 inch above the collar. Then, close the vent.

Metal-Free Cartridge:

• Loosen the cap slowly to allow fuel to drain from the housing.
• Remove the cap, cartridge, and gasket (if present).
• Take out the cartridge and old O-Ring from the cap. Dispose of these parts according to local regulations.
• Clean the cap and housing with a clean cloth to remove any dirt or debris.
• Fit a new O-ring and cartridge into the cap.
• Install a new gasket, if needed, and then install the cap with the new cartridge.
• Tighten the cap to the proper torque specification.
• Prime the fuel system per the manufacturer's instructions.
• Start the engine and check for leaks.

Donaldson gasket removal

To remove a gasket from a Donaldson fuel filter, you will need to follow a few simple steps. Firstly, unscrew and remove the old filter, making sure to dispose of it according to local regulations. Next, wipe the filter head with a clean cloth.

Now it's time to focus on the gasket. Apply a thin film of clean motor oil to the gasket. Then, align the threads and spin the filter on until the gasket makes contact. Follow the icons on the filter to tighten it to the appropriate torque.

Finally, start the engine and check for any leaks. This process should ensure a proper gasket removal and installation, preventing leaks and keeping your engine running smoothly.

Donaldson filter disposal

Firstly, when removing the old filter, it is important to unscrew and carefully take out the filter and gasket. This step should be performed with caution to avoid any spills or messes. The next step is to properly dispose of the used filter according to your local regulations. Each region may have specific guidelines for the disposal of automotive filters, so be sure to refer to the environmental guidelines provided by your local authorities.

After removing the old filter, it is recommended to wipe the filter head with a clean cloth. This step helps ensure that any residual oil or dirt is removed before installing the new filter. It is also important to note that you should not pre-fill the new filter with fuel unless otherwise specified by the manufacturer.

The disposal process may vary depending on the type of Donaldson filter you are using. For example, if you are using a Spin-On Fuel Filter Water Separator (FFWS), there are specific additional steps to follow. After removing the old filter and gasket, you should wipe the filter head and fill the dirty side of the filter with fuel as per the engine manufacturer's recommendations. It is crucial to consult the instructions provided by the manufacturer to ensure proper disposal and installation techniques.

In summary, Donaldson filter disposal involves carefully removing the old filter and gasket, disposing of them according to local regulations, and cleaning the filter head. By following these steps and adhering to local guidelines, you can ensure the safe and responsible disposal of Donaldson filters. Remember to refer to the specific instructions provided by Donaldson for your particular filter type.

Donaldson filter head cleaning

Step 1: Disconnect the Water-In-Fuel (WIF) Sensor

If your fuel system is equipped with a Water-In-Fuel (WIF) sensor, begin by disconnecting it. This sensor is designed to detect water in the fuel and will need to be reconnected after cleaning and servicing.

Step 2: Unscrew and Remove the Old Filter and Gasket

Using the appropriate tools, carefully unscrew and remove the old fuel filter and gasket. Ensure you follow proper disposal procedures for the used filter, adhering to local regulations.

Step 3: Clean the Filter Head

Take a clean cloth and wipe down the filter head thoroughly. It is important to remove any dirt, debris, or residue from the filter head to ensure optimal performance and prevent contamination.

Step 4: Refill the Fuel Filter (for Spin-On Fuel Filter Water Separator)

If you are using a Spin-On Fuel Filter Water Separator, refill the dirty side of the new filter with fuel, following the engine manufacturer's recommendations. This step ensures that the filter is ready to start trapping contaminants upon installation.

Step 5: Prepare the New Gasket

Apply a thin layer of clean motor oil to the new gasket. This helps create a tight seal and prevents leaks.

Step 6: Install the New Fuel Filter

Align the threads of the new fuel filter with the filter head. Spin the filter onto the head until the gasket makes contact. Follow the icons on the filter to tighten it to the appropriate torque specification.

Step 7: Reconnect the Water-In-Fuel (WIF) Sensor

If you disconnected a WIF sensor in Step 1, now is the time to reconnect it. Ensure it is securely connected to the fuel filter assembly.

Step 8: Prime the Fuel System

Follow the manufacturer's instructions to prime the fuel system. This step ensures that any air is removed from the system, allowing for proper fuel flow and engine performance.

Step 9: Start the Engine and Check for Leaks

Start the engine and carefully inspect for any fuel leaks. Ensure that all connections are secure and tight, and there is no fuel dripping or leaking from the filter assembly.

By following these steps, you can effectively clean and maintain your Donaldson filter head, ensuring optimal fuel filtration and engine performance. Remember to refer to your engine manufacturer's guidelines and always practice proper safety precautions when working with fuel systems.

Donaldson filter replacement

Donaldson fuel filters are designed to help prevent premature injector and pump wear by delivering clean fuel to your engine. The company offers a full range of fuel filters for popular heavy-duty on- and off-road engines.

To replace a Donaldson fuel filter, start by unscrewing and removing the old filter and gasket. Be sure to properly dispose of the used filter according to local regulations. Next, wipe the filter head with a clean cloth. Do not pre-fill with fuel unless otherwise specified. Apply a thin film of clean motor oil to the gasket. Align the threads and spin the filter on until gasket contact is made. Follow the icons on the filter to tighten it to the appropriate amount. Finally, start the engine and check for leaks.

Spin-On Fuel Filter Water Separator (FFWS)

If you have a Spin-On Fuel Filter Water Separator (FFWS), there are a few additional steps. First, disconnect the Water-in-Fuel (WIF) sensor if present and reconnect it after servicing. Unscrew and remove the old filter and gasket, disposing of them properly. Wipe the filter head with a clean cloth. Fill the dirty side of the filter with fuel per the engine manufacturer's recommendations. Apply a thin film of clean motor oil to the gasket. Align the threads and spin the filter on until the gasket contacts, then tighten it to the appropriate amount using the icons on the filter as a guide. Replace the water collection bowl gasket if applicable. Prime the fuel system per the manufacturer's instructions, then start the engine and check for leaks.

Davco®-Type Cartridge

For a Davco®-Type Cartridge, start by removing the vent cap and seal, then remove the collar, cover, and seal. Take out the cartridge and old grommet, disposing of them properly. Clean the collar, cover, and threads. Check the new grommet and install the cartridge. Install the seal, cover, and hand-tighten the collar. Fill the cover with fuel. Fit the new vent seal and cap, then hand-tighten. Start and warm up the engine, increasing RPM for one minute. Slowly open the vent cap until the fuel rises 25mm / 1 inch above the collar, then close the vent.

Metal-Free Cartridge

To replace a metal-free cartridge, begin by loosening the cap slowly to allow the fuel to drain from the housing. Remove the cap, cartridge, and gasket (if present). Take out the cartridge and old O-ring from the cap, disposing of them properly. Clean the cap and housing with a clean cloth. Fit the new O-ring and cartridge into the cap. Install the new gasket (if needed) and install the cap with the cartridges. Tighten the cap to the proper torque. Prime the fuel system per the manufacturer's instructions, then start the engine and check for leaks.

Donaldson Filter Options

Donaldson offers filter options to fit all common primary and secondary systems used on equipment today, including spin-ons, fuel-filter-water separators, DAVCO-type cartridges, and metal or metal-free cartridges. They also offer a full line of cartridge replacements for DAVCO® Fuel Processors, commonly used as primary fuel filter water separators on many medium- and heavy-duty vehicles.

Available Media Types

Donaldson fuel filters use a variety of media types, including cellulose, treated cellulose, and Synteq™. Cellulose is a cost-effective media that meets application efficiency and capacity requirements. Treated cellulose is used for fuel-filter-water separators and helps with effective water separation. Synteq™ is a multi-stage coalescing technology that delivers industry-leading performance.

Frequently asked questions