Procedures

WATER-IN-FUEL SENSOR

Removal

All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Disconnect both battery ground cables.







3. Drain the fuel conditioning module by removing the drain plug.
- Reinstall the drain plug once the fuel conditioning module is drained.







4. Disconnect the water-in-fuel sensor electrical connector.







5. Note the orientation of the water-in-fuel sensor locating guides.

6. NOTE: Use care when removing the water-in-fuel sensor. If the sensor is damaged during removal, the fuel conditioning module cover must be removed and the module cleaned to remove any pieces of the damaged sensor.

Using an appropriate tool, turn the water-in-fuel sensor at least 45 degrees counterclockwise.

7. Pull the water-in-fuel sensor straight out of the fuel conditioning module.
8. Inspect the water-in-fuel sensor for damage.Make sure that there are no pieces broken off of the sensor.

Vehicles with a damaged sensor







9. Disconnect the fuel tubes from the fuel conditioning module.







10. Remove the screws and manifold cover.
11. Clean the inside of the fuel conditioning module, making sure that any loose pieces of the water-in-fuel sensor are removed.

Installation

Vehicles with a damaged sensor







1. Install a new manifold cover seal and clean the seal mating surface.







2. Install the manifold cover and screws.
- Lubricate the manifold cover seal with clean motor oil just before installing the cover.
- Tighten to 5 Nm (44 lb-in).







3. Connect the fuel tubes to the fuel conditioning module.

All Vehicles

4. NOTE: Make sure the water-in-fuel sensor hole is clean.

Lubricate the water-in-fuel sensor hole and water-in-fuel sensor seal with clean motor oil.







5. NOTE: The guides on the water-in-fuel sensor should be pointing down.

Align the water-in-fuel sensor to the water-in-fuel sensor hole and insert the sensor.

6. Using a rubber mallet, gently tap the water-in-fuel sensor into place. Pull on the water-in-fuel sensor to verify that it is securely in place.







7. Connect the water-in-fuel sensor electrical connector.
8. Prime the fuel system by turning the key on 3 times, for 30 seconds each time.
9. Start the vehicle and idle for one minute while noting engine performance.
10. If engine is running rough, check for air leaks.
11. Shut the vehicle off and inspect for fuel leaks.