Changing Water In Fuel Sensor: A Step-By-Step Guide

Water in the fuel sensor is a common issue faced by Ford Powerstroke Diesel owners. This can be caused by a build-up of dirt and grime in the water separator housing, leading to a faulty water-in-fuel (WIF) sensor. To resolve this issue, it is recommended to clean or replace the WIF sensor. The process involves removing the front cover of the HFCM, draining the fuel, and cleaning or replacing the sensor. While this task can be completed within 30 minutes, it is important to ensure that the system is free of air bubbles after reassembly to avoid further issues.

Cleaning the water separator housing

To clean the water separator housing, begin by locating the fuel water separator in your vehicle. This is usually installed below the fuel pump or fuel filter. Once located, confirm that the engine has been turned off and cooled to a safe temperature.

Next, carefully inspect the housing for any signs of damage or oil leaks. If cracks or leaks are present, the housing will need to be replaced. Assuming the housing is intact, check the drain valve to ensure it is closed. If the drain valve is damaged or unable to close, it will also need to be replaced.

Now, open the drain valve and drain some fuel. Observe the discharged fuel to check for the presence of water or impurities. If water or impurities are found, further inspection and maintenance of the fuel water separator are required.

If everything appears normal, you can proceed with cleaning the water separator housing. Start by opening the drain valve to empty any remaining fuel and water from the separator. Then, spray the surface of the separator with a suitable cleaner, covering the entire surface. This will help to soften any impurities or deposits.

Gently wipe down the surface of the separator with a cleaning brush or soft cloth to remove any attached impurities or deposits. Be careful not to use a brush that is too hard, as this may damage the surface. Finally, rinse the separator with clean water to remove any remaining cleaning agents or impurities. Allow the separator to dry naturally or use a hairdryer to speed up the process.

Once the separator is completely dry, you can reinstall it into the fuel system, ensuring that new seals are used to create a tight seal.

Removing the sensor

To remove the water-in-fuel sensor, start by turning off the engine and allowing it to cool down to a safe temperature. This is important for your safety and to avoid any damage to the engine or its components. Once the engine is cool, locate the fuel water separator, which is usually installed below the fuel pump or fuel filter. You can refer to your vehicle's manual or machine drawings to pinpoint its exact location.

Next, carefully inspect the housing of the fuel water separator for any signs of damage or oil leaks. If you notice any cracks or leaks, the housing will need to be replaced. Assuming the housing is intact, proceed to check the drain valve to ensure it is closed. If the drain valve appears damaged or refuses to close properly, it will need to be replaced as well.

Now, we can move on to the sensor itself. The water-in-fuel sensor is typically located within the fuel water separator housing. To access it, you may need to remove the outer housing that encloses the fuel lines. Before doing so, make sure you have a suitable container to catch any fuel or water that may spill out. Place this container under the drain valve, then gently open it to release any remaining fuel and water.

With the outer housing removed, you should be able to locate the water-in-fuel sensor. It is often tubular in shape, with electrical contacts positioned about a quarter-inch away from the aluminum housing. The sensor may be covered in algae or debris, so it is important to clean it carefully before attempting to remove it. Use a suitable cleaner to spray the surface and loosen any built-up gunk. Then, gently wipe it down with a soft cloth or brush, being careful not to damage the sensor or its contacts.

Finally, to remove the sensor, you will need to disconnect the electrical plug that connects it to the rest of the system. This should be a simple process of unplugging the wire from the sensor. Be aware that the rubber gasket behind the sensor may be swollen and difficult to remove. If necessary, use grease or petroleum jelly to help loosen it and reinstall the outer plate.

Once the sensor is disconnected, carefully set it aside and proceed with cleaning or replacing it as needed. Remember to exercise caution and avoid using excessive force when handling the sensor, as these components can be delicate and prone to breakage.

Replacing the sensor

To replace the water in the fuel sensor, you will need to purchase a new sensor. You should also drain the water from the fuel filter and consider replacing the fuel filter as well.

Step-by-Step Guide to Replacing the Sensor:

• Purchase a new sensor that is compatible with your vehicle's specific year, make, and model.
• Locate the water in fuel (WiF) sensor. It is usually found at the bottom of the OEM fuel filter housing.
• Remove the old sensor. This may involve unscrewing or unbolting it from the housing. Be careful not to damage the surrounding components.
• Install the new sensor. Ensure it is securely fastened in place.
• Refill the fuel filter with fresh fuel.
• Prime the fuel system to remove any air bubbles. This may involve cycling the key as if you have just changed your fuel filter.
• Start your vehicle and let it run for a few minutes.
• Check for any warning lights or error messages related to water in the fuel.
• If the issue persists, you may need to repeat the above steps or consult a mechanic.

Additional Tips:

• Regularly drain your fuel water separator to prevent water buildup and reduce the risk of engine damage.
• Consider replacing the fuel filter, especially if it is old or contaminated, to ensure optimal performance.
• Consult a mechanic or a trusted online forum for vehicle-specific instructions if you are unsure about any steps.

By following these steps and staying vigilant about water in your fuel, you can help maintain the health of your engine and fuel injection system.

Cleaning the HFCM housing

To clean the HFCM housing, start by locating the HFCM under the driver's side door on the inner frame rail. Open the drain valve on the side with an Allen head wrench or, if you have the updated drain, simply open it by hand. Let it drain into a pan until it is just dripping. You may also want to remove the filter to get more of the fuel out.

Next, you will need to disconnect the fuel lines. For the front two fuel lines, use a Ford fuel line disconnect tool. Push in the tool that fits the line while pulling the line toward the tool. You will feel it release, and then you can slide the line off. The rear lines have a plastic button that you press to release. Press the button, pull toward the pump, and then slide the line off.

Once the fuel lines are disconnected, you can remove the electrical connectors. There are typically two or three, depending on whether you have a fuel heater. These connectors have typical press-to-release clips.

With the electrical connectors removed, you can now remove the HFCM from the frame. There are three nuts holding the unit in place. Remove these nuts and slide the HFCM off the frame. Work it out carefully, as there is a drive shaft in the way.

Now you can access the HFCM housing. Remove the four tiny bolts on the top cover and clean out any built-up gunk or debris. You can use brake cleaner and a flat-head screwdriver to remove stubborn deposits. Be sure to clean the entire housing thoroughly before reinstalling.

After cleaning, replace the gasket and reverse the disassembly process to put everything back together. Tighten all connections and close the drain valve. Turn the key on and off a few times to prime the system and allow the fuel pump to pressurize the lines. Your truck should now be ready to start.

Checking for leaks

If you suspect that your car is leaking fluid, the first thing to do is to make sure that the fluid is actually coming from your car. If you've parked in a public place, the fluid could be from another vehicle. To check, take a torch and look under the car for signs of leakage, such as a trail or shine on a component.

To determine the source and type of fluid, slide a piece of white cardboard under your car to collect the drips. This will help you identify the fluid and assess the severity of the leak.

If the fluid is clear and water-like, it is most likely water. This is usually nothing to worry about and is often caused by condensation from the air-conditioning unit or exhaust. It could also be caused by your windscreen washers. However, if there is a large amount of water leaking, it may be a good idea to check for any other issues.

On the other hand, if the fluid has a brownish tinge and appears multicoloured when the light hits it, you are likely dealing with a fuel leak. Petrol and diesel will also have very strong, distinctive scents. Fuel leaks are highly dangerous as the fuels are flammable, so you should not drive your vehicle if you suspect a fuel leak. These leaks are often caused by a crack or hole in the fuel tank, which a mechanic can patch up.

Red fluid leaking from the middle or front of your vehicle usually indicates a transmission fluid leak. This can be dangerous, as your car may not run properly, so you should avoid driving and get your car towed to a garage for repairs.

If the fluid is amber, brown, or black, it is likely engine oil. To fix this, try to locate the leak and, if possible, repair it yourself. If you can't fix it, make sure your oil tank is always filled to the appropriate level to prevent damage to your engine, and take your car to a mechanic.

Frequently asked questions