Long story short, I have aftermarket aluminum oil and fuel filter caps, made by an as-yet unnamed company. I've had them since March, so this is my first time trying to take them off since I put them on. The oil filter cap and the lower fuel filter cap, which are both the same size, work fine. The upper fuel filter cap though, that's another story.
When I first installed it months ago it went on a little rough. But it went on, so I didn't think too much of it. It's getting to be time to change my filters, so I tried to take it off today, with terrible results. The oil filter cap came off fine, but not that f'n fuel filter cap. After breaking several wrenches and adapters, including a 3/8" breaker bar (without using a cheater pipe), I gradually moved up from large crescent wrenches, to pipe wrenches, and finally to a 48" pipe wrench on the outside of the cap. I could kinda get that to work with a cheater pipe, to effectively make a 7' wrench, but I could still barely move it when I put all I had into it. And I'm not exactly a small guy. It's WAY too much torque to be putting on something like that, I'm not sure why I took it as far as I did. I included a couple photos for reference, it's not pretty. I could have gotten a longer section of pipe and kept trying, but I probably would have broken something else so I didn't see the need. Just getting that cap to where it is was incredibly difficult. It wasn't getting any easier, and it's not even close to being off.
In any case, I'm resigned to the fact that I'll have to replace the entire housing and filter, which will be a couple hundred bucks I suppose. That doesn't thrill me right now, but whatever. I looked over the workshop manual and it looks like a fairly straightforward process to swap it out, and I think the only consumable parts are a couple of sealing washers. The instructions make me really glad I don't have EGR coolers to get in the way of things.
My questions are, can I reuse the banjo bolts and other hardware, or should I replace these along with the washers? And more importantly, how likely is it that metal shavings could have found their way past the filter housing? And if they have, what's the best way to keep those or other contaminants from entering my fuel system? I really really really don't want this to cause further issues down the road, so I'd like to keep nasty things out of my fuel.
Any help or insight would be appreciated.
And one other thing: I think I'm going to need to replace some or all of my rockers/pushrods/etc at some point. Should I tie that in with this repair, or just worry about that when it becomes more of a problem? Adding that in seems like it would make the job a lot more difficult (and expensive), but I don't know.