11/7/2018 Fuel Filter (Spin-On Type)

Preparatory Steps
 CAUTION 
Drain the water/fuel into a container and dispose of in
accordance with local environmental regulations.

Use the filter drain valve to drain fuel out of the filter for
approximately 5 seconds. This will eliminate fuel from running
over the top of the filter upon removal.

Clean
Clean the area around the fuel filter head.

Initial Check
Plug the fuel outlet line from the fuel filter.
Note : All fuel must be drained from the fuel lines, if
observed.
Apply the vacuum test to the fuel system and check the
vacuum gauge. The upper range of the vacuum should be
between 381 to 508 mmHg [15 to 20 inHg]. The vacuum can
not exceed 508 mmHg [20 inHg].

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11/7/2018 Fuel Filter (Spin-On Type)

If the system holds the vacuum (if the reading on the gauge
does not reduce, the vacuum should not drop more than 2.54
mm Hg [0.1 in Hg] in a minute), then there is no leak in the fuel
system.
Note : The vacuum test is completed if the fuel system
holds vacuum for at least 5 minutes.
If the system does not hold vacuum (the reading on the gauge
does not hold and reduces to 0 mm Hg [0 in Hg]), then there is
a leak in the fuel system.

If the fuel system holds a vacuum (no leak at the fuel filter),
inspect the lines and fittings that were disconnected for any
damage.

If the system does not hold a vacuum, check for leaks at the
fuel filter or fuel line fittings.

Inspect the fuel filter and the fittings. Replace and install parts
that are malfunctioning or damaged.

Remove
Disconnect the water-in-fuel sensor from the wiring harness.

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11/7/2018 Fuel Filter (Spin-On Type)

Remove the fuel filter.

Drain the fuel filter, and remove the water-in-fuel sensor from
the fuel filter.

Inspect for Reuse

Inspect the water-in-fuel sensor for cracks or damage.

Install
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11/7/2018 Fuel Filter (Spin-On Type)

Install the water-in-fuel sensor into the new fuel filter.

Refer to Section V for fuel filter part number(s).

Lubricate the o-ring seal with clean lubricating oil.

Replace the o-ring.

Lubricate the o-ring seal with clean lubricating engine oil (15W-
40).
Note : The engine has a self-priming, low-pressure
system that will fill the fuel filter.

 CAUTION 
Mechanical overtightening will distort the threads, filter
element seal, or filter can.

Install the filter as specified by the filter manufacturer.

Connect the water-in-fuel sensor to the wiring harness.

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11/7/2018 Fuel Filter (Spin-On Type)

Prime
Turn the key to run but do not start the engine for 30 seconds.
The electric fuel pump will run and purge air for approximately
30 seconds. After 30 seconds, attempt to start the engine. If
the engine does not start, turn the key to the OFF position for
approximately 30 seconds, allowing the electronic control
module to power down. Turn the key to the ON position,
allowing the electric fuel transfer pump to cycle again. After 30
seconds, attempt to start the engine again.
If the engine cranks for 30 seconds without starting, prime the
fuel supply lines.
To prime the fuel supply lines, loosen the banjo fitting on the
fuel pump inlet. Run the electric fuel transfer pump until all the
air has been vented. When all air has been vented from the
system, tighten the fitting.
Note : Manual priming is required if:
Fuel injection pump is replaced
High-pressure fuel line connections are loosened or fuel
lines replaced
Initial engine start-up or sta-up after an extended period of
no engine operation occurs
Vehicle fuel tank has been run until empty.
Operate the engine, and check for fuel leaks.

Last Modified: 04-May-2004

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