I mostly lurk and learn as this is my first diesel vehicle. You guys are a wealth of knowledge. Thanx! I just did a shade-tree fuel filter upgrade and thought I'd submit it.
I read this thread with interest because after 28,000 miles on my 05 the sump of my fuel filter canister was clean. Then came ULSD. After 10,000 more miles on a 10 micron filter I switched to a 7 micron filter and found a tan residue in the bottom of the filter cup. Power seemed the same but my mileage was down, and I thought the injection sounded like it was firing harder. I figured you can't have fuel too clean so looked at the Glacier Diesel add-on 2 micron filter kit. Looks like a nice quality kit with those sweep ells. Talked with a neighbor about what I wanted to do and to my delight he dug out a used filter base complete with an old fleetguard filter. Its bracket almost matched the holes in the Cummins intake manifold. Only one manifold hole had threads so I had to drill the other a few thousandths bigger and tapped it for 10mm to match the threads on the other hole. Found a fleet supplier and bought a Fleetguard FF 5320, 2 micron filter to make sure it fit the filter base. I then toted the filter base down to a hose shop and purchased several 3/8 NPT brass tees and two 5/16 barbed hose fittings. The extra ports on the tees were reduced to ¼ NPT for fuel pressure sending devices, which I placed on the output side. Geno's was back ordered on my choice in fuel pressure gauge so to get the installation operational I opted to put in a simple oil pressure sending unit (for an idiot light) from an old VW bug. It comes on at 2-3 psi. I don't have any performance boxes (perhaps some day) so opted to stay with the existing fuel line size to keep the installation simple, figuring I could upgrade later if necessary. I didn't mess with the banjo fittings, instead removed the pinch clamps on the rubber hose connecting line from the bottom of the stock fuel filter canister to the Bosch high pressure pump. The rubber hose then came off easily. I routed new hose from the stock filter canister banjo line to the intake fitting on the new filter base, and lightly clamped in place with worm drive clamps. Did the same from the output side of the filter base to the line to the Bosch high pressure pump. When I filled the FF 5320 with fuel I deliberately filled it from the input holes and was surprised how fast the 2 micron element flowed fuel to the center. There seemed to be very little restriction. I haven't pulled our 10,000 pound trailer yet, and probably won't til I get the gauge installed, but so far everything seems to be working fine using only the stock fuel pump in the tank. If I can find a suitable place to mount the idiot light I plan to leave it in addition to the gauge. I tried to keep everything very clean when I put it together. If you see anything I did that may cause a problem please let me know.