Changing Fuel Water Separator: A Guide For Cummins Engines

The fuel water separator in a Cummins engine is an important component that helps to protect the fuel injection pump by removing water and contaminants from the fuel. Over time, the fuel water separator can become clogged with debris and water, reducing its effectiveness. Therefore, it is essential to regularly drain the fuel water separator and replace the filter to ensure the smooth operation of the engine. While some people choose to perform this task themselves, others prefer to seek assistance from a dealer or a mechanic. The frequency of replacement varies among Cummins owners, with some changing it every 10,000 miles, while others opting for a 15,000-mile interval.

There are also conversion kits available on the market that can simplify the process of changing the fuel filter and make it more accessible. These kits eliminate the need for the original equipment-style filters, saving users money in the long run. Additionally, some Cummins owners have installed secondary fuel filters and water separators as a precautionary measure to better protect their engines from water and contaminants.

Drain the fuel/water separator regularly

It is important to drain the fuel/water separator regularly. This is because, over time, water will collect at the bottom of the canister. Draining the fuel/water separator will prevent water from entering the fuel injection pump, which could cause damage.

The frequency with which you should drain the fuel/water separator depends on a few factors. Some people suggest draining it every time you fill up with fuel, while others suggest doing it every other fill-up. However, many people in the Cummins forum suggest draining it every 10,000 miles or every other oil change. Ultimately, it is up to you how often you do it, but it is important to check it regularly and drain it when necessary.

To drain the fuel/water separator on a Cummins engine, first place a drain pan under the drain hose. Then, with the engine not running, rotate the drain valve handle counter-clockwise to the open (drain) position. Hold the drain valve open until all water and contaminants have been removed and clean fuel exits. Once you have drained all the water and contaminants, rotate the valve handle clockwise to the closed position.

It is also a good idea to clean the area around the sensor and check the condition of the sensor O-ring, replacing it if it is damaged. This will help ensure that the sensor is working properly and can detect the presence of water in the fuel.

In addition to regularly draining the fuel/water separator, it is also important to use high-quality fuel and fuel filters, and to change your fuel filters regularly. This will help prevent water and contaminants from building up in your fuel system and protect your engine.

Use a ziplock bag on the rear filter to avoid diesel spillage

When changing the fuel water separator on a Cummins engine, you can use a ziplock bag on the rear filter to avoid diesel spillage. This is a useful technique to prevent the diesel fuel from getting all over you and your driveway.

Before beginning, make sure you have the necessary tools and safety equipment, including gloves and eye protection.

• Park your vehicle on a level surface and engage the parking brake. Allow the engine to cool down if it has been running recently.
• Locate the fuel water separator. It is usually mounted near the fuel tank or on the engine. Refer to your vehicle's service manual if you are unsure of its location.
• Place a large ziplock bag, preferably a freezer bag, under the fuel water separator to catch any diesel that may spill during the removal process. You can also use a cookie sheet or a tray to catch the spills.
• Loosen the fuel water separator by turning it counterclockwise. Have a container ready to catch the drained diesel.
• Once the separator is loose, slowly turn it further to break the seal. Be careful, as diesel fuel may start spilling at this point.
• Continue turning the separator to fully remove it. Allow the diesel to drain into the ziplock bag or your container.
• Carefully remove the ziplock bag with the spilled diesel and dispose of it properly. Do not spill the diesel on the ground or down the drain.
• Proceed with the rest of the fuel water separator replacement process, including installing the new separator and ensuring all connections are secure.

By using a ziplock bag, you can effectively catch and contain any spilled diesel fuel during the removal of the fuel water separator. This helps to avoid mess and reduces the risk of diesel spilling onto your skin, clothes, or the environment. Remember always to dispose of the spilled diesel appropriately and never pour it down the drain or onto the ground.

Compare prices for filters online and at dealerships

When it comes to purchasing a fuel water separator filter for your Cummins engine, you have the option of buying online or from a dealership. Comparing prices between these two options is essential to getting the best value for your money. Let's take a look at the price ranges for filters from both online retailers and dealerships.

Online Prices for Fuel Water Separator Filters:

Online retailers, such as Amazon and eBay, offer a wide range of fuel water separator filters for Cummins engines. The prices for these filters can vary, but generally, they are more affordable than dealership prices. For example, on Amazon, you can find fuel water separator filter sets for the 2019-2024 Dodge Ram 2500, 3500, 4500, and 5500 6.7L Diesel Turbo Engines. These filters are priced at around $25 to $39, which is significantly lower than dealership prices. Additionally, online retailers often offer free shipping and convenient delivery options, making it a cost-effective and convenient choice.

Dealership Prices for Fuel Water Separator Filters:

Dealerships typically charge a premium for fuel water separator filters. For instance, a user on the Cummins Forum reported that their dealer charged them $150 for the fuel filter and an additional $150 for the fuel/water separator. This is significantly higher than the prices found online. While dealerships may offer the convenience of having the filter replaced for you, the cost can be much higher. It is worth noting that some users have mentioned that certain dealerships may try to upsell or overcharge for these filters, so it is essential to be aware of the average market price before making a purchase.

Benefits of Online Purchasing:

Online retailers, such as Amazon, often offer a wider variety of options when it comes to fuel water separator filters. You can find filters from different brands and compare prices easily. Additionally, online reviews from other customers can provide valuable insights into the quality and performance of the filters. This can help you make a more informed decision before purchasing. Furthermore, online retailers often have competitive pricing, and you may be able to find discounts or deals that can further reduce the cost.

Benefits of Dealership Purchasing:

While online purchasing offers many advantages, there are also benefits to considering dealerships. Dealerships can provide expert advice and guidance on choosing the right fuel water separator filter for your specific Cummins engine. They may also offer additional services, such as installation or maintenance packages, which can be convenient if you are not comfortable performing the replacement yourself. Dealerships typically have established relationships with manufacturers, ensuring that you receive genuine and high-quality parts.

In conclusion, comparing prices for fuel water separator filters between online retailers and dealerships is crucial to making an informed decision. Online retailers, like Amazon, often offer more affordable options with a wide range of choices. On the other hand, dealerships may charge a premium but can provide expert advice and additional services. By weighing your priorities and considering your budget, you can decide which option best suits your needs when it comes to purchasing fuel water separator filters for your Cummins engine.

Consider a conversion kit to save money on filters

When it comes to changing the fuel water separator on your Cummins engine, a conversion kit offers a cost-effective and convenient solution. By opting for a conversion kit, you can save significantly on filter costs and benefit from easier maintenance.

The conversion kit is designed to replace the rear fuel/water separator on your 2013-2023 Ram/Cummins truck. It includes both primary and secondary filters, eliminating the need for an additional filter on the engine. This not only saves you money but also makes filter changes more accessible and less messy. With the conversion kit, you gain the flexibility to choose from a wide range of filter brands, including Cat filters, and you're no longer limited to expensive OE-style filters.

The plug-and-play design of the conversion kit ensures a straightforward installation process. It connects directly to the factory fuel lines and bolts securely in place of the original filter head. Additionally, the kit addresses the WIF light issue in 2019 and newer trucks by including a pigtail that eliminates the need for any wire cutting or splicing.

For further enhancements, an optional fuel heater can be added to the kit. This fuel heater connects directly to the factory harness, utilizing the existing fuel heater circuit with minimal fuss. It's important to note that for certain truck models, such as the 2019-2023 DRW, minor modifications may be required during installation due to exhaust hanger bracket clearance issues.

By choosing a conversion kit, you not only streamline the process of changing your fuel water separator but also make filter maintenance more affordable and convenient.

Install a lift pump

To install a lift pump, you will need to purchase a lift pump kit. These are available from a variety of suppliers and can be purchased to match the size of your setup.

First, you will need to decide where to mount the lift pump. It is recommended to mount it near the fuel tank, as this will make it easier to connect to the fuel lines. Once you have chosen a location, use the mounting hardware included with the kit to secure the pump in place.

Next, you will need to connect the lift pump to the fuel lines. This will involve cutting into the existing fuel lines and installing a T-fitting or similar connector. Be sure to use fuel line quick-connect plugs to cap off any open factory fuel lines and prevent fuel from leaking out.

Finally, you will need to connect the lift pump to a power source. This can be done by splicing into an existing power circuit or by running a new power line directly from the battery. Be sure to use a fuse or circuit breaker to protect the pump in case of a power surge.

Once the pump is installed, be sure to prime it before starting the engine. This can be done by cycling the push-start button several times without touching the brake pedal.

By following these steps, you can successfully install a lift pump on your Cummins engine, providing better filtration and extending the life of your CP3 pump.

Frequently asked questions