How to Replace O-Rings in a DW Surge Tank

Quick answer

Replacing O-rings in a DeatschWerks 5.5L surge tank is a straightforward maintenance task that prevents fuel leaks and ensures a reliable seal. Use the dedicated DW replacement O-ring kit for a correct fit.

Step-by-step O-ring replacement process

1. 1. Depressurize and drain the system: Disconnect the fuel pump relay or fuse and run the engine until it stalls. Then remove the fuel cap and disconnect the battery negative terminal. Drain the surge tank by siphoning or using the drain plug if equipped. Common mistake: Skipping depressurization can cause fuel spray when you open the tank.
2. 2. Disassemble the surge tank lid: Remove the retaining ring or bolts securing the lid. Carefully lift the lid straight up to avoid damaging the O-ring groove. Set aside any gaskets or spacers in order. Checkpoint: Note the orientation of the original O-ring before removal so you install the new one the same way.
3. 3. Remove and clean old O-rings: Use a plastic pry tool or your fingers to lift out the old O-rings from the lid groove and any fitting ports. Wipe the grooves clean with a lint-free cloth and isopropyl alcohol. Inspect the groove for cracks or burrs. Common mistake: Using a metal tool can scratch the groove surface, creating a leak path.
4. 4. Install the new O-rings from the kit: Take the O-rings from the DW replacement kit and place them into the clean grooves. Press them evenly with your fingers—do not stretch or twist. Ensure each ring sits fully seated without rolling. Checkpoint: Apply a thin film of silicone-free lubricant (like WD-40 or fuel-resistant grease) to the O-ring to prevent pinching during reassembly.
5. 5. Reassemble and test for leaks: Replace the lid and torque the retaining ring or bolts to the manufacturer's specification (typically 8-10 ft-lb for bolts). Reconnect the battery and fuel pump relay. Turn the ignition to ON (without starting) to pressurize the system, then inspect for leaks around the lid and fittings. Common mistake: Overtightening can distort the O-ring and cause leaks. Use a torque wrench if specified.

Product facts

• Replacement Oring Kit for DW 5.5L Surge Tank: This kit includes the necessary O-rings for routine maintenance or rebuilds of DW 5.5L Surge Tank models. Using the correct kit ensures each O-ring matches the original groove depth and material, reducing the chance of leaks after reassembly.