How to Change a Fuel Water Seperator

  • 2-3 hours
  • Beginner
  • 25-50
What You'll Need
New fuel separator
Drip pan
Protective overalls
Working gloves

A fuel water separator removes the contamination that causes over 95 percent of fuel pump and injector failure. When it is installed and maintained correctly, it reduces or eliminates excessive exhaust emissions, costly fuel pump and injector repairs, as well as costly downtime. Water and contaminants directly affect the service life and performance of the engine. If they are not properly eliminated from the system they erode, cause surface pitting, and bring about fuel loss and poor performance.

Regular maintenance and inspection of the component can minimize such problems. In case a fuel water separator is worn out, replace it using the following steps.

Step 1 – Release Pressure

Remove the fuel pump relay in the relay box. Undo the gas cap to remove residual tank pressure. Turn on the engine and let it run for a few minutes. It should run until it stalls. To relieve all the fuel pressure from the gas tank, crank it a few times until it is empty.

Reattach the fuel pump relay. Avoid tuning on the key as it will run the fuel pump and try to re-pressurize the system.

Step 2 – Disconnect Hoses

Place some rags under the fuel filter to catch any fuel. Exercise caution when working around fuel. Do not smoke or use flammable materials. Position a drip pan under the filters as well. Use a wrench to loosen fuel hose pipes. A flat head screwdriver can be used to pry the fuel lines of the old fuel filter. Disconnect the hoses and drain any oil into the drain pipe.

Step 3 – Remove Fuel Water Separator and Fuel Filter

Remove the brackets holding the filter in position and lift the filter from its mounting position. Inspect the fuel water separator for wear and tear. If it is damaged then it is better to replace the entire fuel filter unit with a new one.

Inspect fuel hoses that are attached to the filter, if they are worn out then consider replacing them with new ones.

Step 4 – Install Filter

Mount the filter on its position, the flat side should face the engine. Attach the brackets to the filter to secure it and reattach fuel hoses to the filters. Only connect quality hoses to the unit. Tighten the fuel hoses using clamps, torqued to 0.8 to 1.1 foot lbs.