Not much exciting happening this week, too much work, too much music (not complaining about the latter).
I haven’t used Rivnuts before, I assumed that you needed a special and expensive tool to install them. When I removed the diesel fuel filter housing to clean up the bulkhead during my heater project I found that it was fixed with two enormous self-tappers. The rear of the housing is chambered and this part of the bulkhead is made of very thin steel so when the screws had been tightened the steel was distorted and pulled into the chambers. Also the position of the filter was such that opening the drain wasn’t as easy as it could have been.
I straightened the steel as best I could, cleaned, treated and painted it, squirted Waxoil into the cavity, then made a small plate to cover the mass of holes.
I found many YouTube videos showing how to install Rivnuts DIY-style, much like the one at the bottom of this page.
I drilled two further holes (just in case there was anywhere without holes!) and fitted the rivnuts very easily using a tool made from an old door latch.
Banjo fitting, copper washers
I wanted to ‘clock’ the banjo union on the filter inlet so the fuel hose could be routed more neatly so I fitted two new copper washers (ESR354) and pointed it downwards instead of forwards. I installed the filter on the bulkhead with M8 bolts into the rivnuts, cut two lengths of new fuel hose and connected with new jubilee clips. It feels really secure now and it’s another step towards the general tidying under the bonnet.
In the image you can see that I also fitted rivnuts to the existing holes on the other side. I believe these were there for use with the 2.25 litre N/A diesel engines originally fitted to some Series 3 models. Unfortunately it didn’t work too well there as the steel heater pipe is too close to the drain plug. I understand the Discovery 200tdi filter is much longer than the older units. I may fit an earth bar here in future.
There is no need to prime the fuel filter, although that’s probably the more graceful method, turning the engine on the starter for a few seconds does this. I am just incredibly annoyed with myself that I forgot to add a new filter to my last parts order.
Example video of how to fit rivnuts without the special tool: