Changing The Fuel Filter On A 2009 Chevy Duramax

Changing the fuel filter on a 2009 Chevy Duramax is a relatively simple task that can be done at home. The fuel filter is located on the passenger side of the engine, below the air intake tube. To access it, you will need to remove the passenger-side inner fender, which is held in place by plastic body clips and bolts.

Once you have located the fuel filter, the next steps are to:

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

- Remove the fuel filter by rotating it counter-clockwise.

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

- Install a new o-ring on the water-in-fuel sensor assembly and lubricate it with clean engine oil.

- Lubricate the new fuel filter gasket with clean engine oil and install it.

- Install the new fuel filter by hand, ensuring the water-in-fuel sensor connector does not become entangled.

- Locate and open the bleed valve and pump the plunger on the fuel filter housing until fuel flows out.

- Close the bleed valve and reinstall the inner fender and intake tube.

- Start the engine and check for leaks.

Remove the passenger side inner fender

To remove the passenger side inner fender of a 2009 Chevy Duramax, you will need a trim fastener removal tool or a flathead screwdriver, a 10mm socket and socket wrench, and medium-size channel lock style pliers.

First, remove the centre air intake tube between the air filter housing and the turbocharger. Next, remove the plastic body clips and two 10mm bolts holding the passenger side inner fender in place.

Now, you can move on to replacing the fuel filter.

Disconnect the water-in-fuel sensor

Disconnecting the water-in-fuel sensor is a crucial step when changing the fuel filter on a 2009 Chevy Duramax. Here is a detailed, step-by-step guide on how to do this:

Step 1: Remove the passenger-side inner fender. This will give you access to the fuel filter and the water-in-fuel sensor. The inner fender is usually secured by plastic body clips and bolts, so you will need to remove these first.

Step 2: Locate the water-in-fuel sensor. It is connected to the fuel filter and has an electrical connector. You may need to refer to your Chevy Duramax manual or consult a mechanic if you are unsure about its location.

Step 3: Disconnect the electrical connector of the water-in-fuel sensor. This will ensure that the sensor is no longer active and can be safely removed.

Step 4: Before removing the fuel filter, place a container under the water-fuel separator drain valve to catch any fuel that may spill. This will help prevent a mess and reduce the risk of fire.

Step 5: Now, you can remove the fuel filter. Be careful when handling the fuel filter, as it will contain fuel. Loosen the filter by rotating it counter-clockwise, then lift it out of its housing. Keep the filter upright to avoid spilling fuel.

Step 6: Once the fuel filter is removed, drain any remaining fuel from it into the container. Be sure to do this in a well-ventilated area to avoid inhaling fumes.

Step 7: Check if the old gasket is stuck to the fuel filter head and remove it if necessary. A gasket that is not properly seated can cause leaks.

By following these steps, you will have successfully disconnected the water-in-fuel sensor and be ready to install the new fuel filter. Remember to refer to your Chevy Duramax manual or seek professional assistance if you have any doubts or encounter any difficulties during the process.

Remove the fuel filter

To remove the fuel filter from your 2009 Chevy Duramax, first remove the passenger-side inner fender. This is held in place by plastic body clips and two 10mm bolts.

Next, locate the water-fuel separator drain valve at the bottom of the fuel filter. Place a container underneath to catch any spills, then open the bleed screw at the top of the fuel filter housing and drain the water separator.

Now, disconnect the water-in-fuel sensor electrical connector. You can then remove the fuel filter by rotating it counter-clockwise, as if you were looking from the bottom up. Keep the filter upright to avoid spilling any fuel.

Once the filter is removed, drain any remaining fuel from it. Make sure that the old gasket isn't stuck to the fuel filter head.

Drain the fuel filter

To drain the fuel filter of a 2009 Chevy Duramax, first remove the passenger-side inner fender. This is held in place by plastic body clips and two 10mm bolts. Next, find the water-fuel separator drain valve at the bottom of the fuel filter. Now, open the bleed screw at the top of the fuel filter housing, and then open the water separator drain valve. Drain the water/fuel into a container and then properly dispose of it.

It is recommended that you replace the fuel filter at this point, but if you are just draining it, simply close the drain valve and remove the fuel hose.

Install the new fuel filter

Now that you have removed the old fuel filter, it's time to install the new one.

First, check if the new fuel filter comes with an O-ring for the water-in-fuel sensor assembly. If it does, replace the old O-ring with the new one. If the water in the fuel sensor assembly is damaged, you will need to replace it with a new one. Lubricate the new O-ring with clean engine oil before installing it.

Next, check if the new fuel filter comes with a new gasket. If it does, replace the old gasket with the new one. Lubricate the new gasket with clean engine oil.

Now, you can install the new fuel filter. Make sure to do this in the reverse order of removal. Do not fill the new filter with fuel. You will prime it after installation. Ensure that the water-in-fuel sensor wire does not get tangled during the process. Install the new filter by hand only. Do not tighten it with tools.

Locate and open the bleed valve towards the driver's side of the fuel priming pump. You can remove the bleed screw to inspect the O-ring. Then, repeatedly pump the plunger on the top of the fuel filter housing until all the air escapes and diesel fuel begins to flow out of the bleed screw orifice. Close the bleed screw—be careful not to overtighten it as it is made of plastic. Clean up any spills to easily detect leaks.

Finally, reinstall the inner fender and intake tube. Start the engine and check for leaks. If the engine runs rough for an extended period, turn it off, re-bleed the system at the fuel filter housing, and check for leaks again (including the bleed screw O-ring).

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