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#1 (permalink) Old 12-17-2006, 07:39 PM
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matteni is hated around these parts matteni is hated around these parts matteni is hated around these parts matteni is hated around these parts matteni is hated around these parts matteni is hated around these parts matteni is hated around these parts matteni is hated around these parts matteni is hated around these parts matteni is hated around these parts matteni is hated around these parts
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540i Fuel Filter - Heeellllpppppp!

Tried to do the fuel filter today and completly struck out! Dear heaven that was a bitch and I am not even done!!!

First, OMG the manual sucks. Doesn't even show all the fuel lines.

Basically if you have done this you know there are 2 lines on each side of this fuel filter. Closest to the front of the car are easy. One is tiny and other is on with normal clamps.

Furthest from the car ONE of the lines was easy. The other going into the high pressure IN was a BIIITTTCCHHHHHHH!!!!

It has these high pressure hose clamps that can not be removed with a screwdriver or socket. They are pressed on and must be cut off. Problem is - how do you cut them off with fuel vapors everywhere. I basically cut in the middle but you still have to get a new hose on so you have to remove one of these clamps. I kept grabbing it with lineman pliers and tried to squeeze the SOB to deform it enough to come off. I worked at that high pressure line for like 1 hour and every time I lost my grip I cut my hand. Did I mention the gas on my hands into the cuts?

Well I went to AutoZone after calling and confirming they sell gas line by the foot. I got there and an old timer tells me that the clamps are high pressure clamps and they don't sell them. He recommended the dealer and said I would have to buy the special tool to put them on. ARGHHHH. What's worse. I have forgotten with all the gas fumes which line is which. There is one line that goes "straight" and the other has a 30 degree bend in it.

Questions:

1) On the 2 lines that go into the filter farthest from the front of the car - The one with the bend is the "IN" or not?

2) What type of clamps does everyone use? What type of hose?

Any help GREATLY appreciated.
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#2 (permalink) Old 12-17-2006, 08:07 PM
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matteni is hated around these parts matteni is hated around these parts matteni is hated around these parts matteni is hated around these parts matteni is hated around these parts matteni is hated around these parts matteni is hated around these parts matteni is hated around these parts matteni is hated around these parts matteni is hated around these parts matteni is hated around these parts
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I took some pics during the install. The first one shows the closest line going into one of the "outs". The high pressure is hidden.

In the second pic the high pressure is visible with the crazy clamps and it must be coming from the bent line.

Does this make sense?

Is the high pressure line a different type of gas line and can I use any clamp or do I have to get special clamps?
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#3 (permalink) Old 12-18-2006, 09:47 AM
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Matteni, did you remove the fuel pump fuse? I didn't read that on your post. This is required in order to relieve pressure.

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#4 (permalink) Old 12-18-2006, 09:53 AM
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Originally Posted by LOS
Matteni, did you remove the fuel pump fuse? I didn't read that on your post. This is required in order to relieve pressure.

LOS
Yes I did remove it and run the engine till it sputtered and died to remove as much fuel from the system as possible. I was surprised how long it ran without pressure and more surprised how much gas was in the lines and in the filter!

BIG QUESTION: What are people using to crimp the IN / High pressure side? Just the worm connectors that were advised against? Am I the only one with the newer engine/filter to try this?
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#5 (permalink) Old 12-18-2006, 02:57 PM
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The clamp you cut off is a regular one-time clamp, unless you have a special set of pliers for those you can't install a new one, you just have to use a regular hose clamp. Maybe it's cause I've worked at a BMW shop for more than 3 years now but I don't understand why you are having such a hard time changing the filterused: All you have to do is take out the screws that hold the cover on and fold it out of the way and keep it out of your way with a bungie cord, take off some clamps, remove the filter mount, swap filters, reinstall filter and install new clamps on hoses then put the cover back on. Should only take 20-30 min tops with basic hand tools.
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#6 (permalink) Old 12-18-2006, 04:04 PM
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Originally Posted by BMWJNKY
The clamp you cut off is a regular one-time clamp, unless you have a special set of pliers for those you can't install a new one, you just have to use a regular hose clamp.
Thank you - an answer to the question!!

Quote:
Originally Posted by BMWJNKY
Maybe it's cause I've worked at a BMW shop for more than 3 years now but
Uh oh. My condescending remarks meeter is on 11 out of 10. I sense comments made to make another human feel less about himself because someone does something every day of their life. Must get haz-mat suit on! :

Quote:
Originally Posted by BMWJNKY
I don't understand why you are having such a hard time changing the filterused:
Dear God it is going to be bad - brace for it!!!!

Quote:
Originally Posted by BMWJNKY
All you have to do is take out the screws that hold the cover on and fold it out of the way and keep it out of your way with a bungie cord, take off some clamps, remove the filter mount, swap filters, reinstall filter and install new clamps on hoses then put the cover back on. Should only take 20-30 min tops with basic hand tools.
There it is. A full description not unlike the Bentley manual minus the steps that one learns working every day in a BMW dealership for 3 years.
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#7 (permalink) Old 12-20-2006, 01:52 AM
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Quote:
Originally Posted by matteni
Thank you - an answer to the question!!


There it is. A full description not unlike the Bentley manual minus the steps that one learns working every day in a BMW dealership for 3 years.
There are no other extra steps other than the ones you read in the Bently and the ones I outlined. I'm sorry if you took my post as condescending, I was just trying to help you out since thats what you came in here and posting about, "540i Fuel Filter - Heeellllpppppp!" The fuel line that is on the car can be reused unless it has been damaged or is looking dry and cracked. The hose routing I'm not sure of off the top of my head, usually i set the new filter on the floor, or my work cart pointed the same way the old one is then swap them so I don't get the lines crossed.
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#8 (permalink) Old 12-20-2006, 01:56 AM
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um whoah, that was kinda rude, he was just trying to help....if you cant handle sarcasm get off the internet...its full of sarcasm...[/lesson]

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#9 (permalink) Old 12-20-2006, 04:07 PM
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matteni is hated around these parts matteni is hated around these parts matteni is hated around these parts matteni is hated around these parts matteni is hated around these parts matteni is hated around these parts matteni is hated around these parts matteni is hated around these parts matteni is hated around these parts matteni is hated around these parts matteni is hated around these parts
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um whoah, that was kinda rude, he was just trying to help....if you cant handle sarcasm get off the internet...its full of sarcasm...[/lesson]
Are you being sarcastic?
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#10 (permalink) Old 12-20-2006, 04:11 PM
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There are no other extra steps other than the ones you read in the Bently and the ones I outlined. I'm sorry if you took my post as condescending, I was just trying to help you out since thats what you came in here and posting about, "540i Fuel Filter - Heeellllpppppp!" The fuel line that is on the car can be reused unless it has been damaged or is looking dry and cracked. The hose routing I'm not sure of off the top of my head, usually i set the new filter on the floor, or my work cart pointed the same way the old one is then swap them so I don't get the lines crossed.
It is all good. I did get the new line at Autozone (they do sell a high pressure GoodYear line) and some normal 1/4" clamps (probably could have stayed all metric but oh well).

The biggest problem is not knowing how to get the old clamps off (can't really cut them off with fuel/vapers around) and how much force it takes to move the SOBs on off (little WD40 always helps). I put it back together and everything held for over 10 minutes while I tested it. No worries and thanks again for the answer.
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#11 (permalink) Old 12-20-2006, 04:45 PM
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There is nothing to worry about when cutting off the clamps except getting fuel in your eyes. Yeah some may spill on the ground but it isn't more than a few ounces at most. Running the car until it stumbles by taking the fuel pump fuse out isn't a good idea cause you run the risk of running an injector dry, making it hard to restart the car again. A good pair of side cutters will cut right through the one-time clamps, it wears them out fast though cause the metal is tough. This is the advantage to having major brand tools cause when my cutters get dull I can swap them out for free with a new pair when the tool guy comes by.
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#12 (permalink) Old 12-20-2006, 05:47 PM
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Originally Posted by gotKRAUT
...if you cant handle sarcasm get off the internet...its full of sarcasm...[/lesson]
WHAT? OMG! Surely you're full of shit!

All great things are simple, and many can be expressed in single words: freedom, justice, honor, duty, mercy, hope.
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#13 (permalink) Old 12-20-2006, 05:59 PM
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WHAT? OMG! Surely you're full of shit!
lol

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