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  1. #1
    Member
    Join Date
    Jul 2004
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    Durham
    Posts
    57

    Installing a hpdi high pressure fuel filter

    This filter is supposedly one of the culprits leading to failures of these 3.3 liter hpdi's. After changing mine at the recommended 100 hrs. (93 actual hrs.),I have a hard time believing that theory. The old one was absolutely spotless,but at $90 I wasn't going to place the new one on the shelf. And, I wasn't going to spend another $150 to have my dealer install one for the first time. So, I thought I'd take the time to show how I done mine,hopefully saving someone else a few $$ down the road.

    Since this filter is inside the vapor canister (complete with an electric fuel pump),lets disconnect the battery before we start.

    It can look a little intimidating when you first see all the hoses and wiring coming from the top,but we're only going to need to remove one of these. This would be the clear oil line at the top right hand side. We also need to remove 2 bolts holding the bracket for the small solenoid oil pump at the end of that clear hose.Now loosen the 3 mounting bolts,2 at the top and 1 beneath. Go ahead and remove the big stainless and rubber washers with the bolts,or you'll be looking for them inside the cowling later.



    Now we can swing the tank out far enough to drain it,via the small brass plug at the bottom (makes good use of that ugly coffee mug you got for christmas). Next remove the 9 screws holding the canister together,and carefully separate the top from the tank. We don't want to tear the rubber gasket,if you forgot to order a new one (yeah, I forgot). There's a big float assembly inside,so easy does it when working the half's apart.


    The fuel pump may come along with the tank,or it might stay with the lid. The yellow fuel filter is beneath the pump. It took me a little to figure out how to get the filter off,but it simply needs to twist counter clockwise before pulling it down and out. After twisting the new one in place,line the pump up and push it back into it's cavity under the lid. Two O-rings will hold it there,until the tank is back in place.




    The rubber tank gasket will need to be stuck to the tank,before we can ever hope to re-install it. I used just enough RTV silicone in the grove to hold the gasket. Less than a drop will do the whole thing. We don't want any of this squishing out,plugging that high dollar filter. Wipe any excess off with a rag,before sliding the tank back into place.

    I also replaced the racor filter while I was at it,then used the primer bulb to prime the system again. There is a valve-stem bleeder on top of the vapor canister,to release the air that the fuel is displacing. The float in the tank will stop you when it's full,causing the bulb to get hard.

  2.  
  3. Member
    Join Date
    Jul 2004
    Location
    Durham
    Posts
    57
    #2

    Re: Installing a hpdi high pressure fuel filter (flatlander)

    I also ordered a third filter (actually called a strainer),which is inline right on top of the canister. There's a special connecter that holds the out-feed hose in place. Couldn't figure out how to remove this fitting,maybe one of you have seen these before. I tried everything short of a hacksaw or hammer.

    Could be a one time snap in place fitting,in which case they aught to give you one with that $65 dollar filter.


    Here's the sludge that was stopped by the racor filter. Very fine particles of sand,aluminum,and what ever else makes it into the tank. Never found one particle on the high pressure filter screen,and I have bi-focals now.

  4. Member
    Join Date
    Sep 2005
    Location
    Atlanta
    Posts
    33
    #3

    Re: Installing a hpdi high pressure fuel filter (flatlander)

    For you strianer filter. Make sure the chrome connector is pushed on the way on the nipple. Now see that black collar that is sticking out from under the chrome connector? Next you need to take a flat blade screw driver and press that black collar back into the chrome connector making sure the chrome connector is still fully seated on the nipple. You need to keep the black collar seated into the chrome connector as you pull the chrome connector off the nipple. Good Luck.

  5. Member
    Join Date
    Jul 2004
    Location
    Durham
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    57
    #4

    Re: Installing a hpdi high pressure fuel filter (Big Block)

    OK, I'll give that a try the next time I pull the cowling. I did try that,but might not have put enough effort into it. Thanks

  6. Member
    Join Date
    Sep 2005
    Location
    Atlanta
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    33
    #5

    Re: Installing a hpdi high pressure fuel filter (flatlander)

    Just push on the chrome connector toward the filter and depress the black collar and know pull the chrome connector off while keeping the collar depressed inside the chrome connector. It's hard to explain. Goo Luck.

  7. Member
    Join Date
    Dec 2004
    Location
    Washington
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    1,106
    #6

    Re: Installing a hpdi high pressure fuel filter (Big Block)

    I bought the manuals and intend to do this this winter. Changing all the filters and putting in a new water pump. Pictures really look great.



  8. Member
    Join Date
    Jul 2004
    Location
    Durham
    Posts
    57
    #7

    Re: Installing a hpdi high pressure fuel filter (PushNit)

    There's manuals for this??

    Been wanting to pick some up,but haven't done so yet. I'm looking to install a phase II kit this winter,and they might come in handy then.

    I did get to try my fancy yeller low water muffs,when I was checking for fuel leaks. Worked pretty slick. May have ticked off the neighbors though! Love that raw sound of a cackling 2 stroke,especially if you burp her a few times.

  9. Member
    Join Date
    Jun 2004
    Location
    Bonney Lake
    Posts
    45
    #8

    Re: Installing a hpdi high pressure fuel filter (flatlander)

    My mechanic says to use a Yamaha water separating filter in line from the fuel tank to the engine. He said that the Yamaha filter works better than a Merc filter and will help keep the high pressure filter from plugging up. I changed out the the Merc one on my Ranger for the Yamaha and it seems to work great. Two years without changing the high pressure filter. Going to change it this winter.

  10. Member
    Join Date
    Jun 2005
    Location
    Madison
    Posts
    7
    #9
    Excellent post !!

  11. Member
    Join Date
    Oct 2005
    Location
    St.Louis
    Posts
    13
    #10

    Re: Installing a hpdi high pressure fuel filter (flatlander)

    I have a 1999 225 ox66. Is there one of these filters on my engine also? Thanks!

  12. Member
    Join Date
    Sep 2005
    Location
    Atlanta
    Posts
    33
    #11

    Re: Installing a hpdi high pressure fuel filter (2fishy)

    Yes your engine will have the same filter screen in the vapor seperator tank but no the gold colored filter shown above.

  13. Member
    Join Date
    Jan 2005
    Location
    St.Louis
    Posts
    641
    #12

    Re: Installing a hpdi high pressure fuel filter (Big Block)

    Thanks!

  14. Member
    Join Date
    Jun 2004
    Location
    Belton
    Posts
    16
    #13

    Re: Installing a hpdi high pressure fuel filter (flatlander)

    Do you have the yamaha part numbers for the filters you replaced Thanks Tom
    [

  15. Member
    Join Date
    Nov 2004
    Location
    Chesterfield, Va
    Posts
    3,207
    #14

    Re: Installing a hpdi high pressure fuel filter (flatlander)

    Just ordered all my parts to do all my filters today and also add a water/fuel seperator in line. Thanks for showing how easy this is to do, love being able to save some bucks not having to go to the shop


  16. clovisman
    Guest
    #15

    Re: Installing a hpdi high pressure fuel filter (flatlander)

    Wish I had read this couple days ago. Just took my hpdi for service and about craped my pants when I got the bill for replaceing two filters. So these filters have to be replaced every 100 hrs?

  17. Member
    Join Date
    Nov 2004
    Location
    Chesterfield, Va
    Posts
    3,207
    #16

    Re: Installing a hpdi high pressure fuel filter (flatlander)

    Did all of the filters using this post. Did the work over two nights total about 2 hours time. Could not have been easier. Thanks for putting this out there to show us all how easy it is. Now with the money I saved what shall I buy.


  18. Member
    Join Date
    Dec 2004
    Location
    Gonzales
    Posts
    42
    #17

    Re: Installing a hpdi high pressure fuel filter (flatlander)

    Flatlander, Thanks.

  19. Member
    Join Date
    Jun 2006
    Location
    Sweetwater, TN
    Posts
    5
    #18

    Re: Installing a hpdi high pressure fuel filter (flatlander)

    I have an 2006 250 hpdi, I have a clear plastic fuel cylinder that has what looks like a fuel filter inside it and fuel, My first yamahauler so I am a rookie does the o6 have the same setup you describe or do I have a easier job replacing the fuel filter.

    carl4432

  20. Member
    Join Date
    Nov 2004
    Location
    Chesterfield, Va
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    3,207
    #19

    Re: Installing a hpdi high pressure fuel filter (carl4432)

    We have the same set up, that is just one of 3 or 4 filters that have to be replaced.


  21. EJP
    EJP is offline
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    #20

    Re: Installing a hpdi high pressure fuel filter (vafishing)

    Flatlander, thank you for this post. I just did mine, did it fix my problem or not I do not know yet, but your pictures and directions helped me take my tank apart and there was a ood amount of black crud at the bottom that I think was blocking up my screen causing my engine problems...... Thanks to Al for the BBC, and thanks to you for taking the time to post this.

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