Diesel Care Fuel Filter Kits and Catch Can Kits - information booklet by Diesel Care Australia

SINCE 1947 Over 70 years four successful mergers evolved DALBY. GOONDIWINDI. TAMWORTH. TOOWOOMBA.

Designed & built by our experienced team PREMIUM Fuel Filter Kits™ and Catch Can Kits™

Designed to safeguard modern diesel vehicles from expensive fuel system repairs

Modern Diesel Engines equipped with high pressure, electronically controlled fuel injection systems can easily be damaged by contaminated fuel

Types of fuel contamination

Fuel cleanliness is critical for reliability

Fuel contamination can cause costly damage

Sources of contaminated fuel

SOLUTION... Install an additional fuel filter to safeguard Filtering fuel twice greatly reduces the chance of contamination problems

What will an auxiliary fuel filter NOT stop?

Past installations were challenging and time consuming

Our technicians researched and developed a range of custom kits

Diesel Care Fuel Filter Kitsâ&#x201E;˘ were the first to hit the market

Everything included for an easy installation

Custom designed vehicle specific mounting bracket Various shapes and sizes to suit a large range of diesel vehicles

FUEL MANAGERÂ® Filtration System To effectively remove particle matter and water from fuel

Fuel hose, fittings, clamps and fixing hardware

Detailed D.I.Y. Installation Instructions

Vâ&#x20AC;&#x2122;s

Fuel Filter Kit Options

PRIMARY (PRE) Filtration

Plumbed BEFORE the factory filter Coarse filter rated at 30 microns

SECONDARY (FINAL) Filtration

Plumbed AFTER the factory filter Fine filter rated at 2 or 5 microns

What kit do we recommend?

Vâ&#x20AC;&#x2122;s

Effective safety net if contaminants get through the factory filter Removes smaller abrasive particles = less wear on the pump and injectors Removes water if any gets through the factory filter Changed less regularly

The Fuel Manager is the most trusted fuel filter brand on the market Traps impurities and water without impeding flow rate Replacement of elements without the use of tools and without spilling fuel

Testing is an important part of our research and development

How effective are the fuel filters we use in our kits?

Andrew puts dirty fuel into a $70,000 4WD

INSTALLATION TIME? Incredibly easy D.I.Y. install in just over an hour that ANYONE CAN DO!

PRICE RANGE? Superb value for money Kits start from just a few hundred bucks (much less than injector or engine work) Filter Kits are cheap insurance

There is already a factory filter installed, why install another? The factory fuel filter installed does not offer adequate protection for some harsh Australian conditions

Fuel can not be too clean tion Contaminaing penetrat ses u through ca p & costly pum age injector dam

N replacon genuine not fi ement filt requirt for purpo ers e a ba se soluti ckup on

CONTAMINATION EVIDENCE

Sealed only on the metal face

Evidence of contamination Approx. 30,000kms

Sealed with filter paper and glued both top and bottom Approx. 20,000kms

Evidence of contamination

What should I do if the Fuel Filter warning light on the dash comes on? Alert means water detected or blockage in factory filter STOP AND INVESTIGATE Drain and catch some fuel from filter If water evident

replace filters

Does the addition of another fuel filter restrict the flow of fuel? Some aftermarket filters may restrict flow Fuel Manager® FM100

DOES NOT RESTRICT FLOW We’ve built & sold tens of thousands of kits, all of them based on the FM100 filter. If they caused flow restrictions we wouldn’t use them. It’s as simple as that!

Does a secondary fuel filter cause flow restrictions?

Will installing an additional filter kit void the vehicle warranty? Itâ&#x20AC;&#x2122;s unlikely any manufacturer would view this in a negative way, after all, it prevents a known problem FACT: If you get contamination in your fuel system, there is no warranty

Does the filter kit fit when there is a dual battery system in place? Yes, in the majority of applications. There are a few exceptions, but we do our best to design kits that fit with commonly fitted under bonnet accessories

Is the filter easy to replace and maintain? Yes, the filter cartridge is easy to remove No need for hand tools No spills No fiddly O rings or gaskets due to integrated rubber seals

How often should the filter cartridge be changed?

30 MICRON REPLACE EVERY

20,000kms

2 OR 5 MICRON REPLACE EVERY

40,000kms

or every second time you change your factory filter, whichever comes first.

If you encounter contaminated fuel, change the filters early

Replacement filter purchases? You can never have too many spare filter cartridges They vary in micron rating and size Be sure to get the correct one

Filter Assembly Parts

FILTER BLEED SCREW (used for secondary filters only)

FILTER RETAINING RING

FILTER CARTRIDGE

WATER COLLECTION BOWL

FILTER DRAIN VALVE

Filter change instructions

MORE QUESTIONS? JUST ASK!

Designed to prevent soot deposit build-up in the engineâ&#x20AC;&#x2122;s air intake manifold.

A Catch Can is: A bad name for an oil mist separator The solution to blocked intake problems for modern diesel engines

What is EGR? Exhaust Gas Recirculation systems Emission control function to reduce Nitrous Oxide emissions (NOx)

NOx Explained NOx is the reaction of nitrogen and oxygen in the air during high temperature combustion Is a toxic gas that affects both living creatures and plants Forms smog and acid rain to create fine particles and ground level ozone, both of which are associated with adverse health effects

EGR emission control process... Exhaust gases are piped to the air intake system The combustion process is modified Nitrous Oxide emissions are lowered

EGR has some potentially negative side effects Hot exhaust gas contains carbon (soot) and other by-products of combustion Alone the gases are safe traveling through the intake system however when mixed with CCV the side effects begin

What is CCV? Closed Crankcase Ventilation Another Emission control function to prevent crankcase blow-by gases venting to atmosphere

CCV emission control process... The blow-by gases from the CCV are also piped to the air intake system Combustion blow-by gases contain oil mist and water in the form of vapour

When EGR and CCV gases combine... Oil mist mixes with the soot particles A sticky carbon mixture is produced and attaches to the walls of the intake manifold

Carbon deposits build up over time and severely restrict the flow of air

Carbon buildup Problems Reduced performance Limits fuel efficiency Costly to repair

Removing deposits involves disassembly of the intake system from the engine followed by a time consuming and costly cleaning process The on-vehicle chemical cleaning process is possible when deposits are light to moderate

SOLUTION... Install an oil mist separator Rerouting & removing oil mist from crankcase vent gases substantially reduces deposits forming in the intake Prevents costly repairs Helps maintain engine performance and efficiency Critical engine components are kept clean Oil buildup in intercoolers is prevented

Our own range of kits were developed to... Fit better under the bonnet Be more robust in design Easier to install

Premium Kit Design Challenges Vent Hoses have limited flexibility, so when adding bends and corners our design team work carefully to ensure the custom fittings will suit Restrictions with room under the bonnet requires loads of R & D to avoid rubbing and wear on other parts

Everything included for an easy installation

Custom designed vehicle specific mounting bracket Various shapes and sizes to suit a large range of diesel vehicles

Diesel Careâ&#x201E;˘ ProventÂŽ oil mist separator To effectively reduce deposits forming in the air intake

Vent Hoses Custom assembled to suit space under the bonnet

Fittings, clamps and fixing hardware Plus maintenance and service stickers

Detailed D.I.Y. Installation Instructions

Oil Separator Options Best option will vary depending on vehicle make and model

Made by German manufacturer Mann+Hummel, the ProventÂŽ catch cans are high quality Offers highly efficient oil separation Light, robust and compact design Substantial volume to catch oil and exceptional for variable flow rates Integrated safety feature against irregularly high crankcase pressure Maintenance friendly and tested rigorously

MAINTENANCE SCHEDULE Drain oil every 5,000km or earlier Replace element every 40,000km or when oil wetting appears around ProVentÂŽ by-pass valve

ProVent® Parts • • •

•

• •

• Oil

Return

• Replacement • Housing

• Control Valve

• Cover

• Bracket

Element

With Pressure Release Valve

The ProVentÂŽ Oil Separator explained

INSTALLATION TIME? Incredibly easy D.I.Y. install in just over an hour that ANYONE CAN DO!

PRICE RANGE? Superb value for money kits start from just a few hundred bucks (much less than the cost of repair)

TOYOTA - NISSAN - MAZDA - ISUZU - VOLKSWAGON - MITSUBISHI - FORD - FOTON - GREAT WALL - HOLDEN - HYUNDAI - IVECO - JEEP - LANDROVER - MERCEDES - TOYOTA - NISSAN - MAZDA - ISUZU - VOLKSWAGON - MITSUBISHI - FORD - FOTON - GREAT WALL - HOLDEN - HYUNDAI - IVECO - JEEP - LANDROVER - MERCEDES - TOYOTA - NISSAN - MAZDA - ISUZU - VOLKSWAGON MITSUBISHI - FORD - FOTON - GREAT WALL - HOLDEN - HYUNDAI - IVECO - JEEP - LANDROVER - MERCEDES - TOYOTA - NISSAN - MAZDA - ISUZU - VOLKSWAGON - MITSUBISHI - FORD - FOTON - GREAT WALL - HOLDEN - HYUNDAI - IVECO - JEEP - LANDROVER - MERCEDES - TOYOTA - NISSAN - MAZDA - ISUZU - VOLKSWAGON - MITSUBISHI - FORD - FOTON - GREAT WALL - HOLDEN HYUNDAI - IVECO - JEEP - LANDROVER - MERCEDES - TOYOTA - NISSAN - MAZDA - ISUZU - VOLKSWAGON - MITSUBISHI - FORD - FOTON - GREAT WALL - HOLDEN - HYUNDAI - IVECO - JEEP - LANDROVER - MERCEDES - TOYOTA - NISSAN - MAZDA - ISUZU - VOLKSWAGON - MITSUBISHI - FORD - FOTON - GREAT WALL - HOLDEN - HYUNDAI - IVECO - JEEP - LANDROVER - MERCEDES TOYOTA - NISSAN - MAZDA - ISUZU - VOLKSWAGON - MITSUBISHI - FORD - FOTON - GREAT WALL - HOLDEN - HYUNDAI - IVECO - JEEP - LANDROVER - MERCEDES - TOYOTA - NISSAN - MAZDA - ISUZU - VOLKSWAGON - MITSUBISHI - FORD - FOTON - GREAT WALL - HOLDEN - HYUNDAI - IVECO - JEEP - LANDROVER - MERCEDES - TOYOTA - NISSAN - MAZDA - ISUZU - VOLKSWAGON MITSUBISHI - FORD - FOTON - GREAT WALL - HOLDEN - HYUNDAI - IVECO - JEEP - LANDROVER - MERCEDES - TOYOTA - NISSAN - MAZDA - ISUZU - VOLKSWAGON - MITSUBISHI - FORD - FOTON - GREAT WALL - HOLDEN - HYUNDAI - IVECO - JEEP - LANDROVER - MERCEDES - TOYOTA - NISSAN - MAZDA - ISUZU - VOLKSWAGON - MITSUBISHI - FORD - FOTON - GREAT WALL - HOLDEN HYUNDAI - IVECO - JEEP - LANDROVER - MERCEDES - TOYOTA - NISSAN - MAZDA - ISUZU - VOLKSWAGON - MITSUBISHI - FORD -

Will installing a catch can kit void the vehicle warranty? Itâ&#x20AC;&#x2122;s unlikely any manufacturer would view an oil mist separator in a negative way, after all, it prevents a known problem

If carbon build-up is such a common problem why donâ&#x20AC;&#x2122;t manufacturers fit a mist separator in production? A few do... but not many. The focus is more on meeting emission requirements Vehicles are built to a price point so things are left off the list

They werenâ&#x20AC;&#x2122;t needed on older engines, so why are they needed now? Diesel engines before around 2002 did not have Exhaust Gas Recirculation (EGR). Its EGR that causes the problem

Does a Catch Can have any effect on the road worthiness of my vehicle? No, fitting a Catch Can is completely legal

Replacement filter elements? Different elements are available for 150 & 200 Be sure to get the correct one

Outlet

Inlet

Outlet

ProVent® 150 INLET and OUTLET is opposite to ProVent® 200