Replacing Fuel Filter Elements-9230

CAUTION: Due to High Pressure Common Rail system design, fuel in filter is likely to be under high pressure. To avoid possible personal harm, open valve (C) on bottom of water separator bowl to relieve pressure prior to removing each filter.

IMPORTANT: Replace fuel filter elements anytime audible alarm sounds and diagnostic trouble codes indicate plugged fuel filters (low fuel pressure). If no alarm sounds during the 12 month service interval, replace elements at that time, or after 250 hours operation, whichever comes first.

NOTE: Water separator is part of the fuel filter assembly.

1. Thoroughly clean exterior of fuel filter/water separator assembly and surrounding area.

CAUTION: Due to High Pressure Common Rail system design, fuel in filter is likely to be under high pressure. To avoid possible personal harm, open valve (C) on bottom of water separator bowl to relieve pressure prior to removing each filter.

NOTE: Water separator is part of the fuel filter assembly.

2. Drain water and contaminants from primary filter (A) and secondary filter (B) into suitable container by opening drain valves (C) on bottom of filters. Make sure to turn nut past threads until it drops onto plastic tabs.

3. Disconnect the water-in-fuel (WIF) sensor connector from primary filter.

A-Primary Fuel filter
B-Secondary Fuel Filter
C-Drain Valve
D-Water-in-Fuel Sensor

RW29387,00003CC -19-17NOV06-1/2

IMPORTANT: Always replace both filters at the same time.

4. Remove the final fuel filter (B) first, for clearance, using a suitable filter wrench. Then remove primary fuel filter canister (A).

5. Remove primary fuel filter element and replace with new element.

IMPORTANT: Do NOT prefill either fuel filter with fuel.

6. Remove water-in-fuel sensor (D) from old primary filter. Inspect filter O-ring condition and replace if necessary. Install O-ring in new primary filter and tighten to specification.

Specification

7. Remove packing for primary fuel filter canister and replace with new packing provided with filter element. Lubricate packing for primary fuel filter with fuel, and install canister onto base. Tighten 3/4 turn after packing contacts base.

8. Lubricate gasket and install filter onto base. Tighten 3/4 of a full turn after gasket contacts the base. Connect water-in-fuel sensor.

9. Repeat above procedure for secondary filter.

IMPORTANT: Key must be turned to ON position for 60 seconds before starting engine to provide time to prefill fuel filters. Fuel system is self-bleeding.

10. Turn key switch to ON position for 60 seconds to allow transfer pump to prefill fuel filters.

11. Turn key switch clockwise to START position, and run engine at fast idle for 2 minutes. If engine won't start or dies, see BLEEDING FUEL SYSTEM. If engine will not start after bleeding fuel system, prime the system as indicated in RESTARTING ENGINE THAT HAS RUN OUT OF FUEL.

RW29387,00003CC -19-17NOV06-2/2