Tools needed:?
• Filter head rebuild o-rings
• #20 Torx bit
• Large flat head screwdriver
• Small flat head screwdriver
• Ratchet with extensions and 1/2-inch socket (for battery removal)
• 5/16-inch wrench (for battery removal)
• 12mm wrench for filter head removal
Step 1. Remove the filter head using the 12mm wrench.
I like to remove the battery to gain more room and better access.
Step 2. Remove the three #20 torx screws.
Step 3. Using the O-rings from the kit in largest to smallest order, replace the largest O-ring here:
Step 4. On the under side, remove the two #20 torx screws.
Then replace next largest O-ring here:
Step 5. Replace the next largest O-ring here:
Step 6. And finally, the smallest O-ring here:
For the standard kit, put everything back together and you're done. If you bought the deluxe kit that includes the plunger seals, you have two more steps.
The plunger seals are under the metal plunger cap. Remove the old seals and replace with the new seals from the deluxe kit. Note the orientation of the edges of the seals. The top seal edge should be at the top and bottom seal edge at the bottom.
Put everything back together and you're done.
Questions and answers posted on DMax Central forum at www.dmaxcentral.com.
Q: Where did you get the O-ring kit, the dealer?
A: No, the dealer will only sell you a new head (for $400 - $750) with the same poor quality O-rings that dry out, crack and leak air from ULSD and swell and leak air from bioDiesel. I had to source my own parts because none of the aftermarket kits gave me enough information to know if they were the viton that is suitable for 100 percent bioDiesel. (There are several viton specs, and not all are great with biodiesel.)?Anyway, I sourced my own kit with Viton type A O-rings that are great for bioDiesel and even better with pump diesel. I bought in bulk and will be able to offer the kits for only $11 with shipping. That's half the cost of the cheapest I found it online anywhere.