Katerina Swanson
Water in fuel is a common issue faced by owners of Duramax diesel engines. The issue can be caused by contaminated fuel or water ingress during car washes or when driving through puddles. Duramax Supplement Manuals provide instructions on how to drain water from the fuel filter, which typically involves opening a drain valve or petcock at the bottom of the filter. However, some users have reported difficulties in opening the drain valve due to its tightness. Alternative methods include using a pair of channel locks to open the drain cock or unplugging the water sensor to turn off the water in fuel message. Regular maintenance and replacement of the fuel filter are recommended to prevent water build-up and potential damage to the fuel system.
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What You'll Learn
Draining the fuel/water separator
Firstly, locate the fuel filter housing, which is found on the passenger side of the engine. Pull the passenger side fender well on the front to access it. You will need a 7mm socket, a 10mm socket, and a pair of needle nose pliers.
Once you have located the fuel filter, close the drain valve and remove the fuel hose. Then, disconnect the water-in-fuel sensor electrical connector. The filter can now be removed by rotating it counter-clockwise, as if looking from the bottom up. Ensure that the water-in-fuel sensor wire does not become entangled. Keep the filter upright until it is removed from the vehicle to prevent fuel spills.
After removing the filter, drain it and verify that the gasket did not stick to the fuel filter housing flange. Then, remove the water-in-fuel sensor assembly from the bottom of the fuel filter using a wrench, socket, or pliers. Replace the o-ring on the assembly and lubricate it with clean engine oil before installing it onto the new fuel filter. Do not overtighten.
Finally, repeatedly pump the plunger on the top of the fuel filter housing until all air escapes and diesel fuel begins to flow out of the bleed screw orifice. Tighten the bleed screw, clean up any spills, and start the engine to check for leaks.
It is recommended to replace the fuel filter and drain the fuel water separator at regular intervals, depending on the model year of your Duramax vehicle. For 2001 to 2010 models, GM recommends doing this every 15,000 miles, while for 2011 to 2016 models, it is suggested to be done every 22,500 miles or as prompted through the instrument cluster display.
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Removing the fuel filter
To remove the fuel filter on a Duramax engine, follow these steps:
First, locate the fuel filter. The housing is on the passenger side of the engine. Pull the passenger side fender well on the front. You will need a 7mm socket, 10mm socket, and a pair of needle nose pliers. The filter is a big white or black component with a white drain at the bottom and a wire coming out of it.
Next, close the drain valve and remove the fuel hose. Unplug the wire and use channel locks to open the drain cock. Drain the contents into a container, such as an empty water bottle, and inspect the colour. If the liquid is brown, continue draining until you see clear fuel.
Now, carefully tighten the drain cock, ensuring not to overtighten and crack it. Locate the bleeder screw on the top side of the filter head and open it. Use the primer bulb until solid fuel comes out.
Finally, remove the fuel filter by rotating it counter-clockwise, as if looking from the bottom up. Ensure that the water-in-fuel sensor wire does not become entangled. Keep the filter upright until it is removed from the vehicle to prevent fuel spills.
It is recommended to replace the fuel filter and drain the fuel water separator every 15,000 to 22,500 miles, depending on the model year of your Duramax. Additionally, consider removing the passenger side inner fender for easier access to the fuel filter housing assembly.
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Locating the water-in-fuel sensor
To locate the water-in-fuel sensor (also known as the WIF sensor) on a Duramax engine, you must first pull the passenger side fender well on the front. This will expose the fuel filter, which is a large white or black component with a wire protruding from it. The WIF sensor is located at the bottom of the fuel filter and is connected by a two-wire connector. This connector transmits whether the sensor detects water in the fuel.
When removing the fuel filter, the WIF sensor comes out with it. To remove the fuel filter, first close the drain valve and remove the fuel hose. Then, locate and disconnect the WIF sensor electrical connector. Next, remove the fuel filter by rotating it counter-clockwise when viewed from the bottom up. Ensure that the WIF sensor wire does not become entangled during this process.
Once the fuel filter is removed, drain it and verify that the gasket did not stick to the fuel filter housing flange. Then, use an appropriate wrench, socket, or pliers to remove the WIF sensor assembly from the bottom of the fuel filter. If the WIF sensor assembly is damaged, do not reuse it.
The WIF sensor can be replaced, and the replacement part typically costs around $25 with a published labour rate of 1 hour. It is important to note that the sensor does not analyse the fuel for water but instead detects when a certain quantity of water has collected in the filter housing.
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Bleeding the fuel system
To bleed the fuel system, first, locate the fuel filter housing, which is on the passenger side of the engine. Close the drain valve and remove the fuel hose. Disconnect the water-in-fuel sensor electrical connector and remove the fuel filter. Drain the filter and check the gasket and fuel sensor assembly. Replace the o-ring on the water-in-fuel sensor assembly and lubricate with clean engine oil.
Then, repeatedly pump the plunger on the top of the fuel filter housing until all air escapes and diesel fuel begins to flow out of the bleed screw orifice. Close the bleed screw and start the engine, checking for leaks.
If the truck runs rough for an extended period, turn off the engine, re-bleed the system at the fuel filter housing, and check for leaks.
Some Duramax owners have reported issues with bleeding the fuel system, such as difficulty accessing the filter and leaks. One user reported that their fuel filter housing had warped, causing air to enter the system. Another user suggested that a FASS lift pump could be a solution to bleeding issues, as the standard filter housing design is flawed.
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Checking for leaks
To check for leaks, it is recommended to first turn off the engine if it has been running rough for an extended period of time. Then, re-bleed the system at the fuel filter housing and check for leaks, including the bleed screw o-ring.
Before starting the engine, it is important to clean up any spills to easily detect leaks. Once the engine is started, check for leaks again.
If there is a "service water in fuel" warning, open the water drain on the bottom of the fuel filter and drain the fuel/water separator into a glass jar or clean bottle. Let the contents sit and separate to verify if there is water present. If there is water, it is recommended to change the filter.
It is also suggested to check the wires on the water-in-fuel sensor for any exposure or damage, as this can cause the warning to appear even if there is no water in the fuel.
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