Replacing the Fuel Filter on the ZD30 Engine
Replacing the fuel filter on a ZD30 is perhaps one of the simplest things to do, but if done incorrectly, you can end up with a lot of problems with bleeding the fuel system.
According to the regulations, the fuel filter is supposed to be changed once every 30,000 km; the filter can be replaced more often, for example, after 15-20 tkm or after one oil change.
To replace the fuel filter you will need:
- Original fuel filter 16403-59E00,
- 16403-59E0A, 16403-59EXM or cheaper 16403-59EX0
- O-ring for drainage unit 16406-05E00 (not included with original filters)
- Oil filter strap wrench
- Rags
- A tray, jar or any small container for draining remaining fuel from the filter
If you plan to replace the filter for the first time, it is recommended that you order O-ring 16407-W4900 in advance. It may not be on the booster pump due to frequent loss during the last replacement.
The filter must only be original, because non-original filters may differ in throughput and quality of the filter element. Also, you should not skimp on the sealing ring of the drainage unit, because. Air leaks often occur through this ring. The 16403-59EX0 filter does not come with an O-ring.
As a rule, the filter is tightened very tightly, so it is not always possible to unscrew it by hand, and sometimes not even any puller will help. Due to the tightness and small gaps between the filter and the bracket, the use of a chain puller is inconvenient, so the most effective would be a belt puller like the one shown in the photo below, because allows the use of levers of different types and lengths.
There are different methods for replacing the fuel filter. Below we will describe the simplest, fastest and most effective method, in which there is no need to remove the hoses, remove the booster pump from the bracket and pump the fuel system for a long time.
Regardless of the filter replacement process used, it is necessary to try to minimize airing of the fuel system, because long attempts to start the engine with air in the fuel system are not useful for the ZD30 injection pump
Replacing the fuel filter
We thoroughly wipe the filter housing with a rag to ensure good grip for the puller belt and not to stain it, then place the rag under the filter so that spilled fuel does not get on the wiring harness below.
We put the puller belt on the bottom, tighten it and try to unscrew the filter.
When unscrewing the filter, you can hear the sound of air “sucking” - this is fuel leaving the fuel line into the tank.
We unscrew the filter and remove it without turning it over or tilting it, so as not to spill the remaining fuel in it.
If for some reason you cannot unscrew the filter, you will have to disconnect the hoses and remove the filter together with the booster pump from the bracket
We completely unscrew the water drain valve from the drainage unit and check the condition of its rubber O-ring.
We remove the old sealing ring from the body of the drainage unit and thoroughly rinse the drainage unit from dirt from the inside and outside with the remains of diesel fuel from the filter. We also wash the water drain valve.
We put a new sealing ring on the body of the drainage unit and lubricate it with a drop of motor oil or diesel fuel so that when screwed into the new filter it will fit normally.
New filter and screw the drainage unit onto it by hand, after which we also clamp it in a vice, screw it all the way and press it a little.
Lubricate the o-ring of the water drain valve with a drop of engine oil or diesel fuel and screw it tightly into the drainage unit by hand. We put on the water drain tube if it was disconnected.
Before screwing the new filter onto the booster pump, the surface of its sealing ring must also be lubricated with engine oil or diesel fuel.
We screw the filter assembly onto the fitting of the booster pump, but not all the way, leaving a gap of 5-7mm, after which we open the filler cap of the fuel tank and vigorously pump it with a frog until diesel fuel flows out of the gap (don’t forget about the rag under the filter) , which will indicate that the fuel line is pumped and the filter is filled with fuel.
After this, we immediately tighten the filter, first by hand, and then thoroughly wipe it and press it with a puller. The filter needs to be tightened tightly, but there is no need to over-tighten it so as not to deform the seal and cause trouble with subsequent unscrewing.
Before starting, you can depress the gas pedal in advance so that the injection pump pumps the remaining air in the system as quickly as possible. If everything is done correctly, it will start and not stall.
We make sure there are no fuel leaks, wipe up any leaks, if any, and don’t forget to close the fuel tank cap.