Fuel filter removal issue

Tiny
AVALON1995
  • MEMBER
  • 1995 TOYOTA AVALON
  • 200,000 MILES
I'm having an enormous challenge removing the fuel filter. Removing the threaded banjo bolt at the top was very manageable, however, the fuel filter nut at the bottom is extremely difficult. There is hardly any space in there, I've tried spraying PB Blaster, I've tried using a flare nut wrench and locking pliers, but it would not budge at all. Unfortunately, at this point, the nut is totally stripped and rusted. Can you please tell me what options I have to remove it? Is there some type of a special tool I can use or is there an alternative resolution? Thank you!
Thursday, July 23rd, 2020 AT 4:10 AM

37 Replies

Tiny
ASEMASTER6371
  • MECHANIC
  • 52,796 POSTS
Good morning,

At this point, you will need to replace the line from the fuel filter to the tank. Once that is stripped, there is no turning back and with it that way, you have no chance to get it tight enough to not leak.

You need to get the line from the dealer and hopefully they still make it for you. If not, you need to go to a junkyard and find one in good shape.

https://www.2carpros.com/articles/how-to-change-a-fuel-filter

Roy
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Thursday, July 23rd, 2020 AT 5:37 AM
Tiny
AVALON1995
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Alternatively, I was thinking of cutting the fuel line close enough to the fuel filter and connecting a fuel line with a compression fitting that comes already flared with the fitting as shown in the attached picture, instead of replacing the entire fuel line. Does that sound like a good and safe resolution? It's a fuel line repair kit and the part # is Dorman 800-151. Thank you!
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Thursday, July 23rd, 2020 AT 11:01 AM
Tiny
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I am not a fan of those kits. The coupler attaching to a 25 year old line does not sit well with me. It may crush and not seal causing a leak. It is worth a try but make sure you keep an eye on it.

Roy
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Thursday, July 23rd, 2020 AT 11:06 AM
Tiny
AVALON1995
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  • 121 POSTS
So, by using a steel fuel line kit, there might be a chance that the coupler crushes and not seal properly causing a leak due to the age of the car. If I try that method and it doesn't work, can I then also use a rubber fuel line hose with a clamp? I would imagine that a clamp would be very tight and not cause a leak.
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Thursday, July 23rd, 2020 AT 11:29 AM
Tiny
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I would not use a rubber hose either due to the high pressure.

You need steel to contain the pressure.

Roy
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Friday, July 24th, 2020 AT 6:29 AM
Tiny
ASEMASTER6371
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Did you respond? I got an e mail but nothing came through.

Roy
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Sunday, August 2nd, 2020 AT 5:30 AM
Tiny
AVALON1995
  • MEMBER
  • 121 POSTS
Never mind, I think it was by mistake.
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Sunday, August 2nd, 2020 AT 7:30 AM
Tiny
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Okay, no worries.

Let me know if you have any other questions.

Roy
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Sunday, August 2nd, 2020 AT 7:33 AM
Tiny
AVALON1995
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  • 121 POSTS
You had expressed some reservation about using a steel fuel line kit, since there might be a chance that the coupler crushes and not seal properly, thus causing a leak due to the age of the car. If it does end up leaking, is that something that would happen right away once the engine is running or could it happen at some point in the future?

As mentioned, buying an existing fuel line is is another option. Unfortunately, I haven't been able to find a fuel line for my car at a junkyard or even a new one for that matter. Hence, I was considering buying a regular steel line that's designated for fuel and making my own fuel line by creating all the bends at the right spots. I'm sure it will be an interesting project. Is there some sort of schematic for the fuel line that goes from the fuel filter to the fuel tank that you can provide? How long is the fuel line?

Thank you!

Cheers!
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Sunday, August 2nd, 2020 AT 8:31 AM
Tiny
ASEMASTER6371
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Okay, if you do that repair, it could leak at any time trying to mate a new line to a 25 year old line.

Replacing with new is a great idea. I would remove the old line first to get an idea on length. It will also give you the routing. There is not diagram of the routing of the line itself.

You can get the line at a parts store.

Roy
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Sunday, August 2nd, 2020 AT 8:35 AM
Tiny
AVALON1995
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When threading the flare nut into the fuel filter, how tight should it be? What is the recommended torque spec? I understand that it needs to be tight enough, so there won't be a leak, but over-torquing is also a concern.

Thank you!

Cheers!
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Monday, August 3rd, 2020 AT 3:18 AM
Tiny
ASEMASTER6371
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Correct.

The spec is 22 ft. Pounds.

Roy
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Monday, August 3rd, 2020 AT 5:27 AM
Tiny
AVALON1995
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Since using a socket on the flare nut is not an option, how would one use a torque wrench on an open-end wrench or on a flare nut wrench?
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Monday, August 3rd, 2020 AT 11:54 AM
Tiny
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The 6 point socket has a 3/8 hole in the end for attaching a 1 or 3 inch extension so you can use the torque wrench.

Flare nut socket is what you need and a 3/8 torque wrench.

Roy
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Monday, August 3rd, 2020 AT 12:04 PM
Tiny
AVALON1995
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  • 121 POSTS
Can you please show me a picture of what you mean?

Thanks!
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Monday, August 3rd, 2020 AT 12:24 PM
Tiny
ASEMASTER6371
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I attached the set from Harbor Freight for you.

https://www.harborfreight.com/38-in-metric-crowfoot-flare-nut-wrench-set-7-pc-68999.html?_br_psugg_q=flare+nut+wrench+set

Roy
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Monday, August 3rd, 2020 AT 12:30 PM
Tiny
AVALON1995
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Oh, okay! A crowfoot flare nut wrench is what I had in mind as well. When you mentioned a flare nut "socket, " I thought you might be referring to the attached picture.

Thank you!
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Monday, August 3rd, 2020 AT 12:41 PM
Tiny
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That would work as well.

Roy
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Monday, August 3rd, 2020 AT 12:43 PM
Tiny
AVALON1995
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In fact, I think that tool in the picture I attached is probably the ideal tool to use when removing the fuel filter.

By the way, would it be a good idea to put anti-seize on the threads of the flare nut fitting, so that it will be easier to remove it in the future?

Thank you!
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Monday, August 3rd, 2020 AT 12:53 PM
Tiny
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Absolutely not. Add nothing to the threads, Just torque it to spec.

Roy
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Monday, August 3rd, 2020 AT 1:11 PM

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