Ameer Randolph
Removing the fuel filter housing on a Duramax truck can be a challenging task. While some people opt to replace the entire housing, others choose to simply remove and replace the fuel filter itself. This process involves draining the fuel water separator, removing the water-in-fuel sensor assembly, and replacing the o-ring on the sensor assembly. Additionally, it is important to lubricate the new fuel filter gasket and install it properly. For Duramax trucks manufactured between 2001 and 2016, there are specialized products available that can aid in the removal of the OEM fuel filter housing.
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What You'll Learn
Remove upper air intake tube
To remove the upper air intake tube on a Duramax, you must first remove the center air intake tube located between the air filter housing and the turbocharger inlet mouthpiece. You will then need to remove the passenger side inner fender, which is secured by a series of plastic body clips.
It is also recommended to remove the upper air intake tube to make the process of replacing the fuel filter housing easier.
To remove the air intake tube, you will need to unbolt the housing to give yourself enough room to get your hands in a position to pull off the hoses. You may need to purchase a pair of 45-degree needle-nose pliers to unhinge the clamps. Shimmy the clamp to the hose side, not the housing side, to avoid issues when trying to reseat the clamp.
If you plan to reuse the clamps, it is recommended to replace the spring clamps with screw clamps, as the OEM spring clamps may lose their tension.
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Remove fuel lines/hoses
Removing the fuel lines and hoses from the housing is a challenging task. The spring clamps can be particularly difficult to manage. One option is to use a pair of 45-degree needle-nose pliers to unhinge the clamps. It is recommended to shimmy the clamp towards the hose rather than the housing, as this will allow you to open the clamp enough to reseat it.
Some people suggest replacing the spring clamps with screw clamps, as the OEM spring clamps may lose their tension and can be hard to manoeuvre.
To remove the hoses from the housing, you will first need to unbolt the housing to give yourself enough room to work. You can then use an angled pick at the hose end, working your way around the tube to break the rubber bonding to the metal. This will make it easier to remove the hoses.
It is also worth noting that replacing the hoses when changing the filter head is a good idea. You do not need to buy the expensive shaped lines, as 3 feet of bulk hose is enough to replace and prevent kinking.
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Unhinge clamps with 45-degree pliers
To unhinge the clamps with 45-degree pliers, you will first need to purchase a pair of 45-degree needle-nose pliers. These can be bought at Harbor Freight.
The spring clamps can be particularly challenging to remove, so the 45-degree pliers are essential. If you plan to reuse the clamps, be sure to shimmy the clamp to the hose side and not the housing side. This will ensure that the clamp opens up enough to be reseated.
It is also recommended to replace the spring clamp with screw clamps, which can also be purchased at Harbor Freight. The OEM spring clamps may lose their tension after being removed, and they can be very hard to manoeuvre.
To remove the hoses from the housing, you will need to unbolt the housing first. This will give you enough room to manoeuvre and pull off the hoses.
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$16.41 $17.72
Unbolt housing
To unbolt the housing, you will need to remove the upper air intake tube. This will make the entire process easier. You will also need to remove the passenger side inner fender, which is secured by a series of plastic body clips.
The next step is to remove the fuel lines/hoses to the housing. This can be tricky due to the spring clamps, which can be difficult to manoeuvre and may have lost their tension. Needle-nose pliers can be used to unhinge the clamps, and it is recommended to shimmy the clamp to the hose side for easier removal and to avoid damaging the housing. Alternatively, you can replace the spring clamp with screw clamps.
Once the clamps are removed, you can then focus on unbolting the housing. This will give you enough room to manoeuvre and get your hands in a better position to pull off the hoses. It is important to note that the entire process of replacing the fuel filter housing can take around 4 hours, even for someone with maintenance experience.
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Drain water separator
The fuel filter housing is located on the passenger side of the engine and features an integrated fuel plunger to prime the fuel system after replacing the fuel filter. The plunger is required to bleed the fuel system of air after installing a new filter.
To drain the water separator, first, remove the centre air intake tube (between the air filter housing and the turbocharger inlet mouthpiece). Then, remove the passenger side inner fender, which is secured by a series of plastic body clips. You can then attach a small section of 1/4" fuel hose to the water-fuel separator drain valve located at the bottom of the fuel filter. Next, open the bleed screw at the top of the fuel filter housing, and drain the water separator into a suitable container. Dispose of the fuel appropriately.
Some Duramax models have a drain knob at the rear, while others have a single tank filter at the front. Draining the water separator is recommended at 15,000-mile intervals for 2001-2010 models, and every 22,500 miles for 2011-2016 models. However, some drivers report that they have never had to drain the water separator, even after driving tens of thousands of miles.
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Frequently asked questions
Removing the fuel filter housing on a Duramax is a complex process and should only be done by those with mechanical experience. The first step is to remove the upper air intake tube. Then, the fuel lines/hoses to the housing must be removed. The spring clamps can be difficult to manoeuvre, so it is recommended to use 45-degree needle-nose pliers to unhinge them.
To remove the fuel filter housing on a Duramax, you will need a set of tools including an appropriate wrench, socket, or pliers. It is also recommended to have 45-degree needle-nose pliers to unhinge the clamps.
The process of removing and replacing the fuel filter housing on a Duramax can take around 4 hours, although some report it taking an hour.
After removing the fuel filter housing, you should drain the filter and verify that the gasket did not stick to the fuel filter housing flange. You should also lubricate the water-in-fuel sensor o-ring with clean engine oil and install it onto the new fuel filter.
