Carina Fuel Filter Howto

[carve1]

Hi all,

Just wanted to share my experience with the fuel filter given that some here may want to change it at some point. The Carina filter is in a difficult place and is, in my opinion, rather badly designed. I thought I'd put a step by step guide together to help anyone who has to deal with it. It's very long but I was bored today so..

Most of this will be obvious to the experienced mechanic. I've gone into way too much detail - sort of a filter change for dummies , but the fact that fuel dribbles everywhere make the swap over even more of a nuisance...

The top of the filter is a "banjo" union onto a rubber hose, the lower a straight union bolt onto a metal fuel line. Only the bottom one will give significant trouble. I found no crush washers to replace on the bottom union which is probably why the darn thing has to be so incredibly tight. The top has two copper washers, one on either side of the side (banjo) connection.

Firstly, spray top and bottom with WD-40 and leave overnight. The fuel pressure should go to nothing in this time (at least I had no problems), saving you having to relieve the fuel pressure.

Buy a 14 mm flare wrench. I got a 13x14 one from Halfords. This will save you rounding the bottom union bolt. Don't even think about using a shifting wrench/adjustable spanner.

You'll also need a 19mm open spanner, a 17mm socket + extension bar + tbar if you have it. The tbar allowed me to get more torque on the top nut. Also some disposable gloves. Petrol is really unpleasant stuff.

Right. Release the mounting bracket from the bulkhead. Don't bother releasing the filter clamping bolt. Remove the rubber mounting bungs and, using some large washers, remount the bracket to the bulkhead. This secures the filter to the bulkhead in such a way that it is doesn't flex when pressure is applied to the bolts.

The top banjo bolt should loosen easily enough, especially if you have a tbar. With the wd40 soak, it released so easily for me that I managed to punch myself in the nose with one hand and punch something painful with the other. Watch yourself!!! Tighten it back up just enough to stop fuel pouring out...

Use the flare spanner on the bottom (remember to go clockwise!). I couldn't release it and had to do this: I held the filter in place by using a 19mm open spanner on the filter nut, meanwhile my brother (who is stronger) used the flare spanner on the union. A tap with a rubber hammer might help here if there's room - some impact might be necessary.

Once loosened, retighten finger tight to stop fuel pouring out. It might drip. No worries.

The new filter should come with a bung in the top hole and a cap on the bottom. These are useful. First put on some disposable gloves. I had some from a medical supply somewhere that were resistant to petrol. I'm sure Halfords or similar will sell them. They're dead cheap. Eye protection is not a bad idea either.

Fuel on skin is nasty. It itches and burns and is generally unpleasant. The Haynes suggests taping or plugging the fuel lines when you take the filter off - don't bother, it's more trouble. DO NOT try and put your finger over the metal fuel line to stop the flow. You've got your head down in the engine bay and there is just enough head pressure there to spray fuel right into your face as your finger closes the opening. This is not good... Really. Just don't do it (yeah, I did it...)

You won't spill much fuel so don't worry about that. The bit that spills onto the ground will evaporate soon enough. There's simply no room for containers in the engine bay... If you really want to, you could shove a container underneath the car...

Remove the mounting bracket bulkhead bolts. Remove the top banjo union. One of the washers will probably escape - don't worry about it. Use the rubber bung from the new filter to block the hole (might spurt a bit so watch your face). Take the opportunity to remove the clamp bolt and take off the mounting bracket.

Have the cap from new filter and the new filter handy - remove the bottom union (it's captive and there are no washers so there's nothing to catch). Just use your fingers; there's enough to juggle with without adding tools too! Flip the old filter over and cap it. Take the new filter and stick it on the fuel line, screw the union in with your hand as tight as your gloved fingers can get it. Do use your fingers here cause it's way too easy to cross the threads on the lower connector.

The fuel filter will slowly be filling up - should be enough time to grab the old filter, pull the bung out and slap the bung on to the top of new filter. Whew!

Now you can get the mounting bracket, put the rubber mounts back in and fit it to the filter. Put the bracket clamp bolt in first - you'll never get it in if you screw the bulkhead bolts in first. Finally, fit new sealing washers on either side of the banjo union and fit that. I recommend you try and hold the bottom washer up against the banjo with your fingers as you fit it. Once you take the rubber bung out, the fuel dribble tries to wash the washer away - very frustrating.

Tighten the unions. Don't go nuts on the top union - the washers make that unnecessary. Start the car. Note the drip from the bottom union. Stop car, tighten union up, start car, note drip etc etc. It's a pain in the face. I used the 19 mm open and the 14mm flare and squeezed them together with both hands to get the drip to stop. There's not enough room down there to do anything else.

Hope all this helps!

Conor.

[markemd]

Hello Conor, I've just joined the Toyota forum, just so I can send you my thanks for your guidance (from 17 years ago!) on how best to remove the fuel filter on my 1994 Toyota Carina E. I wonder if your Toyota is still going strong? It would have taken me a while to work out how to loosen that invisible 14mm nut underneath; as you say, not the best of designs, nor the easiest filter to replace; but your advice stood me in good stead. Gripping with both hands on the 19mm and 14mm spanners simultaneously (both open ended) did it for me. I would add that it's a good idea to put a big towel/old t-shirt etc under the filter to mop up all the spilled fuel. Just be careful to soak it afterwards and dispose of carefully. Thanks and kind regards, markemd