Your next tank of diesel could be lurking with Water, Microbial growth (bugs) or tiny particals that the factory filter never picks up - They can all destroy your fuel injection system!
DON’T RISK IT, GET EXTRA PROTECTION TO SAVE IT
Modern diesel engines are equipped with advanced high pressure electronically controlled injection systems which can be easily damaged and the biggest enemy of this equipment is poor quality fuel, or more frequently contaminated fuel.
Whether it be water, microbial growth (bugs) or particle matter that gets into jerry cans or service stations in remote places the cost of repairing damage caused by contamination in your fuel can be huge. A Common rail diesel engine rebuild alone can cost over $15,000. So prevention is better than cure.
One way to provide the best protection to your engine is to install an additional fuel filter and water separator. All common-rail systems only have one factory filter, so installing the additional filter included in a Diesel Care Fuel Filter Bracket Kit™ is an absolute must. The full range of D.I.Y. Kits are available to suit a wide range of diesel vehicles have been designed to give you piece of mind and save your pocket.
Filter Kits - Features
EVERYTHING YOU NEED TO DO THE JOB!
- VALUE FOR MONEY
Superb value for money. Full filter kits starting from just a
few hundred bucks (way less than injector or engine work!)
- THE ORIGINAL DIESEL FUEL FILTER KIT
– OFTEN COPIED NEVER EQUALLED
We’re the creators of the ORIGINAL diesel fuel filter kit, that others copy.
We have the largest range of kits because we do the R&D to produced them first.
Which Kit? Primary or Secondary?
WHAT’S THE DIFFERENCE?
Diesel Care offer D.I.Y. fuel filter kits in two variants for most of the vehicle range we cover; Primary (pre) and Secondary (final). We often have people ask what the difference is between our Primary and Secondary Kits, so we’ll explain…
FUEL MANAGER – PRIMARY (PRE) FILTRATION
Primary filters, sometimes called a pre filter are plumbed before the factory filter.
(See image A on the right.) Fuel passes through this relatively coarse filter first before continuing on to the vehicle’s factory installed filter, then to the high pressure pump. The filter media in a Diesel Care Fuel Manager primary filter is rated at 30 micron. A micron is a unit on length equal to one millionth of a metre, or to break this down further; one micron is one thousandth of a millimetre.
So, a 30 micron filter will remove particles the size of 30 x 1,000ths of a millimetre. This may sound very small, and it is, but not small enough to protect modern high pressure fuel systems from abrasive damage. Most factory filters on modern Common Rail systems are rated at 10 micron.
FUEL MANAGER – SECONDARY (FINAL) FILTRATION
Secondary filters, sometimes called a final filter are plumbed after the factory installed filter.
(See image B below). Fuel passes through the factory filter first before continuing on to the secondary filter, then to the high pressure pump.
The filter media in a Diesel Care Fuel Manager final filter is rated at 2 micron or 5 micron, depending on the vehicle. So, a 2 micron final filter will remove particles the size of just 2 x 1,000th of a millimetre. Now that is very, very small!
SO WHICH ONE DO I CHOOSE? PRIMARY OR SECONDARY?
This is where you need to decide. There are a number of differences between both options, and a lot of people ask what we recommend. We’ll get to that later but first we’ll go over the features for both.
PRIMARY (PRE) KIT FEATURES
- The 30 micron Filter effectively removes larger particulate matter
- Effectively removes water
- Prolongs the service life of the factory filter cartridge
- It is recommended that you change the primary filter cartridge at the same time as you would your factory filter unless fuel is contaminated.
SECONDARY (FINAL) KIT FEATURES
- Provides an effective safety net if contaminants get through the factory filter
- The 2 and 5 micron filters effectively remove smaller abrasive particles, resulting in less wear on the pump and injectors
- Effectively removes water if any gets through the factory filter
- The secondary Filter cartridge can be changed less regularly than the primary and factory filter cartridges, we recommend every second time the factory filter is changed unless fuel contamination occurs.
WHAT KIT DO WE RECOMMEND?
Both options will provide much better protection than not having an additional filter. Each one has their advantages but at the end of the day, we recommend secondary. The reason is that we believe that finer filtration ultimately provides better protection. It’s also reassuring to know that if you are unlucky enough to get a bad tank-full of fuel, and the filter warning light on the dash comes on, that if anything has penetrated your factory filter, it’s been caught in the final filter. The fact is; contaminants DO get through filters. As Diesel Injection Specialists we see evidence of this almost daily. The best way to prevent expensive repairs caused by fuel contamination is to filter it. Fuel cannot be too clean.
FILTER CONTAMINATION EVIDENCE
Think it cant happen to you? Here are some pictures of the contaminated fuel filters in a Mitsubishi Triton.
The first picture is the factory filter, this has done approx 30.000ks and there is clear evidence of contamination – the black deposits.
The other is the Fuel Manager secondary filter, it’s done approx 20.000ks – the blackness in this filter is evidence that it is catching contaminates which could have ended up in the engine causing some costly repairs!
It also worth noting that the filter media in the Fuel Manager is Glued top and bottom, where as the factory filter is just sealing the metal faces at the top.
Your next tank of Diesel could destroy you engine.
The protection of an additional fuel filter could save it.
Filter Change Instructions
If you have an additional fuel filter it is important to check the filter cartridge for contamination and change if necessary. This video will show you how to inspect and change a fuel filter.
Diesel Care Filtration Kit Review
A real issue when your out in the bush is the quality of your fuel. Pat Callinan talks about the issue of contaminated fuel when your traveling and good trip preparation by fitting one of our Filtration kits to your 4wd.
Clarcor Fuel Manager - What Does It Offer?
Clarcor Fuel Manager is the versatile Diesel Fuel Filtration / Water Separation System.
We include Clarcor’s FUEL MANAGER FM100 Diesel fuel filters in our Kits because they are one of the most trusted brands on the market. Clarecor are one on the largest filtration companies in America, all they do is filtration, both liquids & gasses. The fuel filtration and water separation needs of today’s new generation diesel fuel systems demand extremely high efficiency, flexibility, multiple functions and ease of use with no risk of fuel spills or contaminated parts.
Clarcor’s patented Fuel Manager® range of combination fuel filter/water separators meets these demanding requirements and are used on hundreds of different machines powered by diesel engines. Over 60 Original Equipment Manufacturers specify the Fuel Manager Fuel filter/water separator systems for their engines &/or equipment. These include; John Deere, Caterpillar, Perkins, Sisu, Case, New Holland, Ford, Volvo, JCB, just to name a few. Available for light, medium and heavy duty trucks; and agricultural, industrial, construction and marine applications, there is a Fuel Manager Series to meet any condition.
THREE SERIES AVAILABLE
FM10 Series – up to 200HP
FM100 Series – up to 350HP
FM1000 Series – up to 600HP
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ENSURES CLEAN FUEL
Specially treated hydrophobic media to remove both water AND particulates. The unique design efficiently traps impurities & water without impeding flow rate.
WIDE RANGE OF SIZES
Clarcor’s massive range of FUEL MANAGER Diesel fuel filters are a unique, patented, modular diesel filter/water separator system that can be customised for virtually any application up to 600HP.
WIDE RANGE OF MICRON RATINGS
The Filter elements are available in 5 different micron ratings: 2, 5, 10, 30, & 150.
While 150 micron is a relatively course filter that will strain particles 150 x 1000ths of a millimetre, the 2 micron will strains particles as small as 2 x 1000ths of a millimetre.
The design permits the replacement of elements without the use of tools & without spilling fuel, making service quick & easy.
Diesel Fuel Additives
As well as protecting your engine diesel fuel additives also improve diesel engine performance.
Diesel Care sells and recommends two separate additives; Stanadyne Performance Formula, & Fuel Doctor. These two additives are quite different in composition; Stanadyne’s additive being petroleum based, Fuel Doctor being detergent based.
Fuel additives are used to upgrade and stabilise fuel by reducing sludge and fuel tank contaminants. They work to clean and protect fuel system components such as the pump and injectors to achieve reduced wear on components and to restore lubricity. In addition, the cetane improver in some fuel additives such as Stanadyne Performance Formula results in easier starting, less smoke and more complete combustion. The net result is more horsepower, more torque and more km per litre. Consequently, a significant cost savings to you.
Regular use of a fuel additive will more than pay for itself by:
- savings at the fuel station
- provide protection to components and reduce the need for repairs
- extend maintenance intervals.
Poor quality fuel leads to poor performance, low efficiency and expensive repairs so used in addition to our Diesel Care filter kits a fuel additive can provide your sensitive injection system with even more protection and overall better engine performance.
Read Article >
Frequently Asked Questions
Filtration Systems FAQs
They vary depending on the make and model of your vehicle starting from $280.
Search for your vehicle here.
All our Fuel Filter Bracket kits have been custom designed to suit a range of specific vehicles Toyota, Nissan, Mazda and more. Unfortunately we don’t have a kit for every make & model but most popular vehicles are covered & our range is expanding continually.
Search for your vehicle here.
I’ve heard lots of horror stories about dirty fuel. I have also read stories online by “experts” that a secondary fuel filter system could actually create more problems than what they fix, such as not providing enough fuel flow. Comments?
We have seen some claims by one or two forum experts, one even suggesting the high pressure Common Rail Pump could run dry. This is complete nonsense. In some instances I agree that an inadequate supply causes problems, e.g. some rotary fuel pumps are very sensitive to restriction (Bosch VP44, Denso ECD-3 & ECD-V4). But in most systems around today, including Common Rail, secondary (final filtration at 2 to 5 micron) is the best thing you could do to increase the life of your fuel system & safeguard against expensive repairs due to fuel contamination.
Some modern vehicles e.g. Toyota, have a restriction indicator to alert the driver if there is a restriction by illuminating a warning light on the dash. A restriction sensor mounted on the factory filter senses any restriction upstream from that point back to the tank, but not a restriction downstream of the sensor, i.e. between the factory filter & the high pressure pump. In the extremely unlikely case of a secondary filter becoming blocked, the restriction sensor would not detect this, however, the worst thing that could happen by having a reduced fuel flow or restricted supply to the high pressure pump is a loss of engine power, or perhaps a surge. These two symptoms are common when a filter becomes blocked, or possibly if a tank puck-up or tank vent is clogged.
We have never seen a fuel restriction lead to the failure of a Common Rail pump. The evidence that a Secondary Filter will not “create more problems than they fix” is with the tens of thousands of Secondary filters currently fitted to vehicles all over Australia. There have been no pump failures, system damage, or any symptoms whatsoever. We have saved hundreds from damage & failure from contamination. We have, however, seen hundreds of Common Rail pumps fail due to fuel contamination where no additional fuel filter has been fitted. Enough said.
Some unsuitable aftermarket filters may present a flow problem but the Fuel Manager FM100 has more than adequate capacity for all 4WD & SUV diesels available today. The Fuel Manager FM100 is designed for use on common rail fuel systems. The flow rate of the filter assembly with a 2 micron filter is rated at 300 Litres per hour and suitable for engines up to 350hp.
Diesel Care has conducted testing & trials over many years to ensure that our kits don’t cause any problems with regards to fuel supply. We have sold tens of thousands of our kits & have had no reported symptoms of fuel restriction causing loss of performance. If there was any problem in this regard we simply wouldn’t fit them.
The filter warning light is to alert you that there has been water detected in the sedimenter part of the filter assembly, & in some vehicles it can also warn of a filter that’s becoming blocked, e.g. Toyota has this restriction warning feature.
Whatever the cause, a filter warning light should not be ignored. You should stop & investigate at the first possible opportunity. The first thing to do is drain off some fuel from the filter drain cock. This is positioned at the base of the fuel filter assembly & because water is more dense than diesel, it will be the first liquid to come out. It’s a good idea to catch what you drain into a receptacle so you can see if water is present, if there is, the warning light should go out once you’ve re-started. This instance of water in the fuel is where a Diesel Care Secondary Filter Kit really pays for itself. i.e. if any water has managed to get past the factory filter it will have been caught in the secondary filter.
If any water has been evident its best to replace the filters. Filters are cheap, water damage is expensive.
Replacement cartridges can be purchased from quality Diesel Injection repair shops by quoting the part number on the filter. By quoting the part number you will be sure to fit the correct filter to your particular vehicle. Filters vary in Micron rating and size, so it’s important to get the right one. We can mail you one if you don’t have an outlet near you, just call 1800 880 150 or purchase online from our diesel-store.
This depends on which Filter Kit you chose; Primary or Secondary.
Primary filters need changing more often than Secondary because they are filtering fuel straight from the tank, whereas Secondary filters don’t need to be changed very often because they are filtering fuel that’s been through the factory filter. So this is the general rule:
• For Primary filters we recommend you replace the cartridge every 20,000kms.
• For Secondary filters we recommend you replace the cartridge every 40,000kms, or every second time you change your factory filter, whichever comes first.
The exception to the above rule would be if you encountered contaminated fuel, in which case you should change the filters early.
Some rotary fuel pumps are very sensitive to restriction (Bosch VP44, Denso ECD-3 & ECD-V4). So in instances like this we recommend a primary filtration at 30 micron as the only option. But most high pressure systems these days including Common Rail are intolerant of contamination & their repair costs are high. Secondary (final) filtration at 2 to 5 micron is the best thing you could do to increase the life of your fuel system & safeguard against expensive repairs due to fuel contamination.
We have spent many hours developing our products, testing, manufacturing and testing again to ensure that our kits are suitable for the DIY’er. Naturally; some basic skills, some mechanical aptitude, & hand tools are required, along with good old fashioned common sense. We try to make our instructions as easy to follow & as clear as we can. Even so, if you get stuck with some minor technicality we are happy to help you out over the phone. Our Techs fit our kits all the time & know all the ins & outs so help isn’t far away.
Installing a water separator filter kit will not affect warranty as it works in conjunction with the original filter. It does not replace the original filter. There may be some reluctance by some vehicle Dealerships to alter the vehicle from standard but we supply our filter kits to a number of dealerships around the country. The fact is; if you get contamination in your fuel system; there is no warranty. We recommend you discuss installing an additional filter with your Service Manager, & explore the “what if’s” with regards to fuel contamination damage to your vehicle. A Service Manager with common sense will see that you are far less likely to incur expense with a Diesel Care kit fitted.
The secondary filters are fitted after the factory filter, Pre filters are before. We use coarse filtration for Pre (30 micron), much finer filtration for Secondary (2 micron). There should be no problem with warranty as we are not removing the factory filter. We supply both Pre & Secondary configurations to a number of vehicle dealers around the country.
Yes the kit is compatible with the flow rate. The fuel managers are designed for common rail systems. The flow rate on the filter assembly we use with a 2 micron filter is rated at 300 Litres per hour and up to 350hp.
Yes, the filter kits are sent out in express post bags so they can be sent to a PO Box
Yes we do take direct deposit. Please contact us and we will supply our bank details.
No, only one filter cartridge comes with the kit however, extra filters can be supplied at an additional cost and can be purchased through our web store or by phoning us on 1800 880 150.
There are two variants for most of the vehicle range we cover; Primary (pre) and Secondary (final).
In short, Primary filters are plumbed before the factory filter and is a relatively course filter rated at 30 microns.
Secondary filters are plumbed after the factory installed filter and is rated at
2 micron or 5 micron, depending on the vehicle.
Read more detailed information on the differences and what we recommend here.
The team at our Dalby branch have put together a short video showing the process on how to check your secondary fuel filter for contamination and demonstrate how simple it is to change.
Notwithstanding the congestion in the engine bay which can make access to filter a bit awkward on some vehicles, the filter cartridge is easy to remove when it’s time to change it. In fact it can be removed without the need for hand tools thanks to the cartridge retaining nut which can be loosened by hand. Another great feature of the Fuel Manager is that the cartridge can be removed without creating a fuel spill, thanks to the enclosed top on the cartridge. This great design also extends to the rubber seals being an integral part of the cartridge so you don’t have to worry about replacing fiddly O rings or gaskets.
Yes, they do fit with a dual battery system fitted in the majority of applications. There are a few exceptions but we do our best to design a kit that fits with commonly fitted under bonnet accessories. We offer a couple of different mounting positions for some vehicles to try & address commonly found space challenges.
You might think that the fuel filter fitted to your car by the manufacturer is adequate protection. Sadly, the truth is often they are not. The very reason we started developing our filter kits in the first place was because we regularly see damage to diesel pumps & injectors from contamination penetrating the factory fuel filter. The damage can be catastrophic & expensive so the best defence is to add an auxiliary filter to clean the fuel better & more thoroughly.
- Our kits are the original kits. Our brackets are designed & developed by Diesel Care’s experienced technicians & are all made in Australia using high quality stainless steel. Our bracket designs are so good they are copied, but they are never equalled.
- The Fuel Manger Filter included in the kit is made in the USA and is recognised as one of the highest quality fuel filter systems on the market.
- Diesel Care kits have been developed as both Primary & Secondary options. None of the copy-cats offer both.
- Because we develop the kits, we have the largest range available.
- Expert advice is only a phone call away. Our Technicians are happy to offer advice with the installation or answer any questions you may have.
- Everything is included in the kit to do the job yourself but if you’re pushed for time or just don’t feel like tackling the job, book into one of our stores and we can fit it for you.
Everything is included to do the job!
– FUEL MANAGER Filtration System, designed to efficiently remove particle matter and water from fuel
– Custom designed vehicle specific bracket
– Fuel hose, fittings, clamps and fixing hardware
– Detailed Instructions provided for an easy installation
What’s not included in the kit?
– General assembly and dismantling tools e.g. spanners, sockets, screwdriver, etc.