JK CRD Aftermarket Fuel Filter Install

[Turismo07]

Hi all,

Here are some pics and details of my install of a Fuel Manager 5 micron filter and water trap mounted under the batt tray.

I installed this to help ensure the injectors got the cleanest possible fuel to help them last longer. This is not JK CRD specific, this applies to all diesels and esp modern diesels.

Every second Toyota or Nissan 4wd is usually running this filter system and they have install kits avail off the shelf. When I originally looked into this within our Jeep community there was not much info floating around, and outside people laughed as why would you take a Jeep anywhere remote enough to pick up dirty diesel anyway.. Whatever, Jeep is my preferred vehicle and I plan on taking my JK to remote places.

I don't have much faith in the stock fuel filter and water trap/sensor system so wanted something a little more proven for peace of mind.

I started off with a universal Fuel Manager kit. Comes with the mount, a 30 micron filter (which I didn't use), some hose, and some hose clamps.

I used a 5 micron filter because the injectors are about 5 micron.

In my pics I am running the bigger of the 2 filters avail and so far it does not hang down far enough for my 35" tyres to hit it. If I was worried I could run the smaller filter which is about half the size, and just change it more regularly.

I used speedflow fittings. Some trial and error was required to figure out what was needed as no one knew what the fuel line fittings were (not even my local Jeep specialist mechanics). So a few trips back and forth to Couplers in Malaga before I got the right ones. In my pic, you need the x2 part numbers for the 5/16th fittings.

You need a special fuel line tool to disconnect and reconnect the fuel line. I don't have one of these so had to use a workshop to actually connect it for me. Any mechanic should have this tool. Took them around 10 mins max.
The fuel line that you tap into is the supply line between the stock fuel filter and the high pressure fuel pump in the engine bay. When you pull the passenger side front inner fender off, its literally the most obvious hose/line you can see. Very easy to access, see my pics.

The bracket I made bolts directly to the firewall and is made to allow fitting of 2 fuel filters if necessary (not for me) or provide me with the flexibility of mounting the single filter assembly inside of the chassis rail. But I have no probs with where its mounted now, its easier to change the filter and drain the water trap so happy to leave it where it is.

The stock plastic inner fender went back on with a little massaging from a heat gun. Literally put heat on the area for about 10 secs and pushed the fender into place and its now shaped perfectly around the filter assembly. If I chose to run the smaller filter, I would not have had to mod the inner fender.

I had my JK dyno'd after the install to see if fuel flow was going to drop off due to an extra fuel filter (and also cos its 5 microns), but no issues at all.

Hope this helps anyone interested.

[Freetripper]

Awesome solution!! Nice work. I have a question though....
Do you access the fuel lines (where the tool fittings req'd) from underneath also? Or did you need to remove the battery tray?
Alot better idea than re-configuring the lines from the tank, and alot cleaner.
Thanks for sharing, I'll be adding this mod to my list of things to do list, as would I'd imagine alot of other CRD owners.


"Dr says I need a backiotomy!"

[Turismo07]

Originally Posted by Freetripper

Awesome solution!! Nice work. I have a question though....
Do you access the fuel lines (where the tool fittings req'd) from underneath also? Or did you need to remove the battery tray?
Alot better idea than re-configuring the lines from the tank, and alot cleaner.
Thanks for sharing, I'll be adding this mod to my list of things to do list, as would I'd imagine alot of other CRD owners.

Thanks.

You can access the fuel supply line by removing the front left passenger inner fender. Just pop that off and lean in over/behind the front left wheel, it's within an arms reach. Very easy.

Note I have flat flares so the wheel arch opening is bigger than stock, but if you have stock flares would still be easy, or just remove the front wheel to create more room. I did mine without removing the front wheel at all.

[StuieG]

What year is your JK? As i've literally just got in from changing my fuel filter and it's located on the chassis rail under the drivers seat. So that where the fuel lines run.

Have you got any pictures of what you did with the pipes? As in splitting them and connecting them etc?

It's a great idea, what kind of money did it set you back?

Cheers

[Turismo07]

Originally Posted by StuieG

What year is your JK? As i've literally just got in from changing my fuel filter and it's located on the chassis rail under the drivers seat. So that where the fuel lines run.

Have you got any pictures of what you did with the pipes? As in splitting them and connecting them etc?

It's a great idea, what kind of money did it set you back?

Cheers

My JK is a 2009. But all JK CRD's have the stock fuel filter in the same location (under the drivers seat bolted to the chassis rail with it's own skid plate).

I have left the stock fuel filter assembly as is. There is nothing wrong with its filtering capabilities, my main issue was that it is terrible at sensing and separating water from fuel. I still change the stock fuel filter every 10,000 kms like normal.

With my secondary system, the aftermarket filter is 5 micron (the stock filter is 10 micron) which is the same as the injector nozzles, so basically I've added a filter into the system than will filter out particles that are bigger than the injector nozzles and could block or cause damage to them. And the Fuel Manager I have used is has a water trap that is proven to be reliable in the 4wd industry.

If someone wanted to get rid of the stock fuel filter assembly completely and run one of these setups, this is possible - although you would need to wire in a resistor into the electrical plug going to the stock fuel filter to trick the ECU that it's still there otherwise you will have a CEL. You would just need to join the supply lines together at the stock filter location and extend the fuel return line all the way to the new fuel filter assembly.

BUT running only a single 5 micron filter may mean that you need to change filters more often as it will be collecting a lot more particles than the stock 10 micron. This is why most people who run these finer filters usually leave the stock one in place to catch all the bigger particles and the secondary filter to catch anything that the stock one doesn't.

There is plenty of info on how to run fuel filters on diesels as it is very common for 4wd touring rigs who maybe spend plenty of time out in remote places where diesel has algae growing in it or condensation building up etc (this can happen very quickly if diesel is left sitting, as opposed to petrol where it can sit for a very long time before becoming contaminated). There just wasn't much info on installing a system on a JK CRD out there.

Total cost was about $250. If I remember correctly it was about $180 for the universal Fuel Manager kit, about $15 for the 5 micron filter cartridge, about $40 for the speedflow fittings, and maybe a few $$ for the metal for the bracket etc. The fuel line tool I am told costs about $10, but I got my local Jeep workshop (not a dealership) to hook up the new connectors and lines and he charged me a 6 pack of beer.

[StuieG]

Thanks mate, I will definitely be doing this at some point

[Fennec of Morocco]

Hello Turismo07, I am very interested in your assembly of a second fuel filter in your JK. I live in the south of Morocco and I think that I meet here similar conditions that in certain parts of Australia: heat, dust and sand, we are at the doors of the Sahara.
I regularly have problems with my injectors that I had to redo several times. Certainly because of the poor quality of the fuel but certainly also because of the dirt in the diesel.
I have questions, if you want to answer: how did you learn that the original filter was 10 microns (I can not find information on top) and that the injectors had a tolerance of 5 microns (idem at the info level). Since your installation you have no problems, no leaks?
Thank you in advance.