Changing Fuel Filters: 92' Ford Diesel Edition

Changing the fuel filter on a 92 Ford Diesel can be a tricky task, but with the right tools and some patience, it can be accomplished. Before beginning, it is important to gather the necessary supplies, including a fuel filter kit, a bucket or tub for draining the fuel, and oil-resistant gloves for protection. The process involves first draining the fuel from the vehicle via the water drain port located on the driver's side. The primary fuel filter cap can then be removed using a 36mm wrench, taking care not to over-tighten or cross-thread the new cap. The secondary fuel filter, located under the hood, can be accessed and removed using a 24mm socket wrench. It is important to note that the fuel filters should be replaced at least twice a year or every 10,000 miles to ensure the health of the fuel system. Additionally, proper disposal of the old filters and any spilled fuel is crucial for safety and environmental reasons.

Drain the fuel

Before you get started, you'll need to gather some supplies. These include a complete fuel filter kit, a pair of oil-resistant gloves, and some rags or paper towels. You'll also need a large basin or bucket to drain the fuel into, and a 6mm Allen wrench.

Now, locate the water drain port under the vehicle on the driver's side. Place your basin or bucket underneath the port, then open the drain and let the fuel flow into the container. Be prepared for the smell of diesel fuel—it's quite strong!

Once the fuel has been completely drained, you can move on to the next step of replacing your fuel filter.

It's worth noting that some sources suggest loosening the fuel filter housing about three turns before draining the fuel. This will prevent additional fuel from entering the housing and minimise waste and mess.

Tips for a smoother process

• Be sure to close the fuel valve located between the fuel tank and the filter before draining. Depending on the fuel level in the tank, fuel may flow into the bowl if the valve is not closed.
• If you're having trouble loosening the filter, try a hammer and chisel to break it free.
• When removing the old filter, watch out for the plastic clips that hold the filter cage or holder. These can easily pop out and fall into the engine bay, so take care not to lose them.
• To prevent dirt from getting into the fuel system, clean the area around the filter first. You can also use cling film to seal off all open pipe connections until the last minute.
• Cover the alternator with a plastic bag, as diesel can spill into it.
• Fill the new filter with diesel or fuel treatment before installing it. This will help with restarting and ensure the engine receives clean fuel.

Remove the primary fuel filter cap

To remove the primary fuel filter cap of your 92 Ford Diesel, you will need a 36mm socket wrench and a pair of oil-resistant gloves. It is important to note that you should have already placed a large basin under the vehicle on the driver's side to catch the drained fuel.

Now, using the 36mm socket wrench, carefully remove the primary fuel filter cap. Along with this, also remove the O-ring. You will find the primary fuel filter cap near the engine, at the end of the fuel pump. Once you have removed the cap and the O-ring, replace them with the new primary cap from the complete fuel filter kit. The new cap should snap right into place in just a few seconds.

Make sure you do not over-tighten the new cap and that you do not cross-thread it. Also, remember to reinstall the allen plug.

Remove the secondary fuel filter cap

To remove the secondary fuel filter cap of your 92 Ford Diesel, you will need a 24mm socket or a 1/2" square drive ratchet. Place a tub or bucket beneath the fuel pump, which is under the driver's door on the frame rail.

Now, locate the secondary fuel filter. It is located back up on the engine, sitting just between the CAC tube and the air intake tube. You will see two lids there, one for the oil filter and one for the secondary fuel filter. The secondary fuel filter lid is the smaller one.

Using the 24mm socket or 1/2" square drive ratchet, remove the black top cap of the secondary fuel filter. Once the cap is removed, take out the fuel filter from the housing and the O-ring from the lid.

Test and restart

Once you have finished replacing the fuel filter, you will need to prime the fuel system and bleed out any air. To do this, turn the ignition to the 'run' position three separate times for 30 seconds each time.

If you fail to properly prime the fuel system, it can cause serious damage to the injectors, and that damage might not be immediately detectable. Damaged injectors can run—seemingly as normal—for a short time after the failure has occurred, so it’s not always apparent that there’s something wrong.

After priming the system, start the engine and take the vehicle for a test drive. If the vehicle is now accelerating properly, then you have successfully replaced the fuel filter.

Clean the area around the filter

It is important to ensure that no dirt gets into the fuel system. Clean the area around the filter thoroughly. You can use cling film to seal off all open pipe connections until the last minute to prevent any dirt from getting into the pipes.

Diesel can also spill into the alternator below. Use a plastic bag to cover it. The pipes on the filter are held in place with red and white plastic clips. You will need to use a small screwdriver or a thin pair of pliers to squeeze the ends and push these out horizontally to release the pipes.

It may be easier if you remove the top strut stiffener plate to gain access to the pipe clips. However, you must not jack up the car with this removed. You can manage without removing this next time you do this because you will know how the pipe clips are removed.

Frequently asked questions