This tutorial is also available in French
➔
Fuel filter bracket change on Defender Td5
Vehicle ➔ Defender 110 Td5 2002
Difficulty ➔ Easy
Time ➔ 1 hour
Summary
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The major problem encountered on the Defender Td5 fuel filter bracket is its degradation (dissolution) by electrolytic corrosion. This corrosion occurs between the aluminum of the bracket and the steel of the 2 fixing bolts (2nd and 3rd photos).
• 1st photo : new fuel filter bracket.
• 2nd and 3rd photos : damaged fuel filter bracket.
• 1st photo : new fuel filter bracket.
• 2nd and 3rd photos : damaged fuel filter bracket.
There are 2 fuel filter brackets for Defender Td5 :
• WJN000020 : for Defender Td5 up to 3A658551 (with water sensor).
• WJN500150 : for Defender Td5 from 3A658552 (without water sensor).
The only difference between these 2 brackets is the presence of the water sensor at the bottom of the fuel filter.
• WJN000020 : for Defender Td5 up to 3A658551 (with water sensor).
• WJN500150 : for Defender Td5 from 3A658552 (without water sensor).
The only difference between these 2 brackets is the presence of the water sensor at the bottom of the fuel filter.
Although our Defender is from 2002, we decided to order reference WJN500150 (without water sensor) because :
• it is cheaper,
• the water sensor is very fragile and a source of problems,
• the water sensor is not really necessary for driving in France.
• it is cheaper,
• the water sensor is very fragile and a source of problems,
• the water sensor is not really necessary for driving in France.
Required Tools
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Packaging :
•
WJN500150 : The bracket is delivered with its fuel filter. The non return valve and the air bleed valve are also included in this kit.
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Remove the RH rear wheel and the fuel filter shield
Op 01
Remove the RH rear wheel (➔ see the tutorial ''Wheel removal on Defender'' Op 01 to 07).
Before working under the vehicle, make sure to secure it properly with jack stands or rigid chocks. Never work under a vehicle supported only by a jack. It is too dangerous.
Op 02
Remove the fuel filter shield (➔ see the tutorial ''Fuel filter change on Defender Td5'' Op 02 to 04).
Remove the fuel filter bracket
Op 03
Identify where the 4 fuel hoses are located.
Op 04
Move aside the protection cover of the connector of one of the fuel hoses. Push by hand.
Op 05
Disconnect the fuel hose :
•
Press the 2 locking tabs (1st photo).
•
Pull by hand (2nd photo).
Op 06
Plug the end of the hose. Use a clean piece of cloth.
Always seal the hoses with rags to prevent any impurities from entering the fuel system.
Op 07
Disconnect the 3 other fuel hoses. Proceed in the same way.
Memorize well which hose goes on which inlet of the filter bracket. Take a photo if necessary. This will be very useful during reassembly.
Op 08
Unscrew the 2 fuel filter bracket fixing bolts. Use the 10 mm socket.
Op 09
Remove the fuel filter bracket with its filter.
We can see that the 2 fixing points of the fuel filter bracket are completely destroyed by electrolytic corrosion (1st photo). It was really time to change it.
Op 10
Remove the 4 connector protection covers. Pull by hand.
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Fit the new fuel filter bracket
Op 11
Fit the 4 connector protection covers on the new fuel filter bracket (WJN500150). Push by hand.
Op 12
Fit the fuel filter bracket on the Defender chassis and screw in the 2 fixing bolts (FS108357). Use the 10 mm socket.
Apply a little copper grease on the thread of the fixing bolts. This will limit oxidation and make it easier to unscrew during the next disassembly.
Op 13
Connect the 4 hoses to the fuel filter bracket. Push by hand.
Fit the 4 protection covers on the connectors.
Imperatively respect the correct positioning of each of the hoses.
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Fit the fuel filter shield and the wheel
Op 14
Fit the fuel filter shield (➔ see the tutorial ''Fuel filter change on Defender Td5'' Op 12 to 15).
Op 15
Put the wheel back in place (➔ see the tutorial ''Wheel removal on Defender'' Op 08 to 15).
Bleed the fuel system
Op 16
Bleed the fuel system and check for leaks (➔ see the tutorial ''Fuel filter change on Defender Td5'' Op 17 and 18).
The End
