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Rust belt fuel filter

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Offline markpank

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Rust belt fuel filter
« on: August 22, 2011, 02:39:48 PM »
Hey guys,
Thought I'd post a little probelm i ran into to see what others have done and help anyone buying a rusted kick.  OK so... I go to replace my fuel filter the other day on my 98 sidekick sport.  That was quickly haulted when an attempt at loosening the banjo bolts revealed they where completely rusted stiff.  Not being able to grind or do any type of cutting or drilling I'm a little stuck on what my options are here.  I would really like to avoid getting new fuel lines so this is where I need your help.  Rather then going through a long search and having my vechile down for a bit I'm seeing what fittings can replace the banjos  ???  At this pooint I'm thinking of using air compressor fittings that will thread into the filter and can be inserted in the fuel lines and hose clamped tight?  If you see any problems in my thinking please advise me as I'd really not like to do this then find out negative side effects later.
Does the banjo controll the amount of pressure the filter See's or will that matter? Has anyone ever done something similar to the air compressor fittings? Made it work on a lawnmower before but I'm not sure if the fittings will stand up to a larger engines fuel pressure.  Any help or any insight on what any one else has done would be a great help.

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Offline talonxracer

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Re: Rust belt fuel filter
« Reply #1 on: August 22, 2011, 03:19:24 PM »
You will need fittings that will hold the higher fuel pressure of fuel injection, hose clamps will fail sooner than later. Soak the fittings for several days with PB Blaster and give her another try. 
Tim "the toolman" Taylor is my HERO !!!

The only GOOD Commie is the commie taking a dirt nap....

Re: Rust belt fuel filter
« Reply #2 on: August 22, 2011, 07:49:22 PM »
Yep, penetrating oil and lots of working the bolt tight and loose.
If that just doesn't work you can disconnect the rubber lines at the tank and engine hard lines if the rust lets you.
If you're absolutely sure you're gonna break the hard line leading to the tank or engine as a last resort you may be able to cut and clamp a different inline fuel filter to the rubber lines. If you have to do this be sure to double clamp and check to be sure there are no leaks.
Proud owner of a low mile 1992 Tracker 4x4 rust bucket.

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Offline markpank

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Re: Rust belt fuel filter
« Reply #3 on: August 23, 2011, 06:15:01 AM »
Yea thoes are all good suggestions, still trying to loosen over the past few days the main problem Im seeing is when i torque enough to (should) loosen the bolts the filter itself is just ripping in half.  Id like to avoid riping the filter apart and then attempt removing the bolt from the threads of the filter. Im going to load up on locking pliers one to the filter itself to prevent the movement, one to the banjo, and one to the bolt.

Anyone ever use AN fittings? I've heard alot of racing stories with them or with quick disconnects.  I guess my main question is about the banjo bolts.  Do they actually regulate the pressure the filter gets via the size of the openings the gas flows through? Or does anyone know any of the specs on the banjos so I could just find another pair and instert them in the lines where the rusty ones are currently?

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Online fordem

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Re: Rust belt fuel filter
« Reply #4 on: August 23, 2011, 06:55:54 AM »
No - the banjo bolts don't have any regulatory function.

Quite frankly, I don't see the issue with sacrificing the filter - as long as the banjo itself remains intact - let the filter go, buy a new filter, two bolts, four crush washers and you're good to go.
'98 SQ420 Grand Vitara
'05 JB420 Grand Vitara
'16 APK416 Vitara
'21 A6G415 Jimny

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Offline FreddyDynamite

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Re: Rust belt fuel filter
« Reply #5 on: August 23, 2011, 06:58:41 AM »
I know the line you are working on all too well.  I had a similar problem but with the other end where it goes into the fuel pump hanger.  You can see my write up on my solution at http://www.zukiworld.com/forum/technical-discussion-beginner-repair/need-fuel-line-help/ .  All I can say is to be very careful with that line...and the fittings (don't round everything off with vicegrips that are attached to the line), they are expensive at $90 for the line and $160 for the pump hanger.  The biggest problem is that the fittings are metric and most places dont carry them...closely followed by the double flared ends  of the line itself.  If you have a spped shop near you, your best bet would be to see it they could custom make you something, preferable hose instead of steel line with crimped on fittings (avoid future rust). Another place to check for having them made is at truck stops, they usually have the tools there to crimp etc...again, the problem will be the metric fittings.  If you cant undo that bolt...or you tweak the line, it is time to get creative...or open your wallet.