‹

Fuel Filter

Powertrain Management › Tune-up and Engine Performance Checks
Unified entry — merged from multiple cross-listed pages in the original manual.
Procedures
Fuel Pump Module - Removal9 steps
⚠ WARNING
Risk of injury to eyes and skin from contact with fuel. Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked and approved containers. Failure to follow these instructions may result in possible serious or fatal injury.
⚠ WARNING
The fuel system is under constant high pressure even with engine OFF. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury.
ℹ NOTE
Prior to removing the fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening.
ℹ NOTE
The fuel pump module has to be properly located in the fuel tank for the fuel level gauge to work properly.
⚠ WARNING
The fuel pump module reservoir does not empty out when the tank is drained. The fuel in the reservoir will spill out when the module is removed.
ℹ NOTE
Do not spill fuel into the interior of the vehicle.
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  1. Drain and remove fuel tank Fuel Tank - Removal.
  2. Position the lock-ring remover/installer into the notches on the outside edge of the lock-ring.
  3. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer.
  4. Rotate the breaker bar counterclockwise and remove the lock-ring.
  5. Mark the fuel pump module orientation.
  6. Raise the fuel pump module out of the fuel tank using caution not spill fuel inside the vehicle.
  7. Tip the fuel pump module on its side and drain all fuel from the reservoir.
  8. Remove the fuel pump module from the fuel tank using caution not to bend the float arm.
  9. Remove and discard the rubber O-ring seal.
Fuel Pump Module - Installation8 steps
⚠ WARNING
Risk of injury to eyes and skin from contact with fuel. Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked and approved containers. Failure to follow these instructions may result in possible serious or fatal injury.
△ CAUTION
Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced.
ℹ NOTE
The main fuel pump module must be properly located in the fuel tank for the fuel level gauge to work properly.
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  1. Clean the rubber O-ring seal area of the fuel tank and install a new rubber O-ring seal.
  2. Lower the fuel pump module into the fuel tank using caution not to bend the float arm.
  3. Align the rubber O-ring seal and rotate the fuel pump module to the orientation marks noted during removal. This step must be performed for the fuel level gauge to work properly.
  4. Position the lock-ring over top of the fuel pump module.
  5. Position the lock-ring remover/installer into the notches on the outside edge of the lock-ring.
  6. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer.
  7. Rotate the breaker bar clockwise until all seven notches of the lock-ring have engaged.
  8. Install the fuel tank Fuel Tank - Installation.
Fuel Pump Module - Removal9 steps
⚠ WARNING
Risk of injury to eyes and skin from contact with fuel. Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked and approved containers. Failure to follow these instructions may result in possible serious or fatal injury.
⚠ WARNING
The fuel system is under constant high pressure even with engine OFF. Until the fuel pressure has been properly released from the system, do not attempt to open the fuel system. Do not smoke or use open flames/sparks when servicing the fuel system. Make sure the area in which the vehicle is being serviced is in a well ventilated area. Failure to comply may result in serious or fatal injury.
ℹ NOTE
Prior to removing the fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening.
ℹ NOTE
The fuel pump module has to be properly located in the fuel tank for the fuel level gauge to work properly.
⚠ WARNING
The fuel pump module reservoir does not empty out when the tank is drained. The fuel in the reservoir will spill out when the module is removed.
ℹ NOTE
Do not spill fuel into the interior of the vehicle.
Fig. 1
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Fig. 2
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Fig. 3
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Fig. 5
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Fig. 6
  1. Drain and remove fuel tank Fuel Tank - Removal.
  2. Position the lock-ring remover/installer into the notches on the outside edge of the lock-ring.
  3. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer.
  4. Rotate the breaker bar counterclockwise and remove the lock-ring.
  5. Mark the fuel pump module orientation.
  6. Raise the fuel pump module out of the fuel tank using caution not spill fuel inside the vehicle.
  7. Tip the fuel pump module on its side and drain all fuel from the reservoir.
  8. Remove the fuel pump module from the fuel tank using caution not to bend the float arm.
  9. Remove and discard the rubber O-ring seal.
Fuel Pump Module - Installation8 steps
⚠ WARNING
Risk of injury to eyes and skin from contact with fuel. Wear protective clothing and eye protection. Risk of poisoning from inhaling and swallowing fuel. Pour fuel only into appropriately marked and approved containers. Failure to follow these instructions may result in possible serious or fatal injury.
△ CAUTION
Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced.
ℹ NOTE
The main fuel pump module must be properly located in the fuel tank for the fuel level gauge to work properly.
Fig. 1
Fig. 1
Fig. 2
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Fig. 3
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Fig. 4
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Fig. 5
Fig. 5
  1. Clean the rubber O-ring seal area of the fuel tank and install a new rubber O-ring seal.
  2. Lower the fuel pump module into the fuel tank using caution not to bend the float arm.
  3. Align the rubber O-ring seal and rotate the fuel pump module to the orientation marks noted during removal. This step must be performed for the fuel level gauge to work properly.
  4. Position the lock-ring over top of the fuel pump module.
  5. Position the lock-ring remover/installer into the notches on the outside edge of the lock-ring.
  6. Install a 1/2 inch drive breaker bar into the lock-ring remover/installer.
  7. Rotate the breaker bar clockwise until all seven notches of the lock-ring have engaged.
  8. Install the fuel tank Fuel Tank - Installation.
Factory service manual
From the 2008 KK factory manual — descriptions, specs, torque & procedures for this part.
FILTER-FUEL📷 1

Description

The fuel filter and fuel pressure regulator are combined within the fuel pump module assembly. They are not serviceable.
SENSOR-FUEL LEVEL SENDING UNIT
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FUEL FILTER/WATER SEPARATOR
The fuel filter/water separator assembly (8) is located on the left-rear side of the engine compartment. The assembly includes the fuel filter (7), fuel heater (1), fuel temperature sensor (5), combination water drain valve/Water-In-Fuel (WIF) sensor (6), and a quick-connect fittings attached at the side of the fuel filter canister.
FUEL FILTER/WATER SEPARATOR📷 1
The fuel filter/water separator protects the fuel injection pump by removing water and contaminants from the fuel. The construction of the filter/separator allows fuel to pass through it, but helps prevent moisture (water) from doing so. Moisture collects at the bottom of the filter.
Refer to the maintenance schedules in the owners manual for the recommended fuel filter replacement intervals.
For draining of water from canister, refer to REMOVAL .
A Water-In-Fuel (WIF) sensor is attached to the bottom of fuel filter element.
The fuel heater and fuel temperature sensor are installed into the side of the filter/separator housing.
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FUEL FILTER/WATER SEPARATOR📷 1
Refer to maintenance schedules, or the Owner's Manual for recommended fuel filter replacement intervals.
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DRAINING WATER FROM FUEL FILTER CANISTER:📷 7
The combination housing drain valve/WIF sensor (6) serves two purposes. One is to partially drain the filter housing of excess water. The other is to partially drain the housing for fuel temperature sensor, fuel filter or fuel heater element replacement.
The filter housing should be partially drained whenever the water-in-fuel warning lamp remains illuminated. (Note that lamp will be illuminated for approximately two seconds when ignition key is initially placed in ON position for a bulb check).
1. A nipple is located at the bottom of drain valve (6). Attach a drain hose to this nipple. Place drain pan under drain hose. 2. With engine not running, Disconnect WIF sensor electrical connector (4) then rotate drain valve (6) approximately two revolutions to open it. Leave open until all water and contaminants have been removed and clean fuel exits. Hand tighten drain valve after tightening. 3. If fuel heater element is being replaced, drain housing completely. Dispose of mixture in drain pan according to applicable regulations. 4. After draining operation, close and tighten drain valve (6).
5. FUEL FILTER REPLACEMENT: 6. Clean all debris from around filter canister (7) and canister head. 7. Open drain valve (6) two complete revolutions. Drain approximately 1 cup of fuel into a waste canister. Dispose of fuel according to environmental regulations. 8. Remove drain hose from drain valve (6). 9. Use an oil filter type wrench to loosen filter (7). Continue removing filter by hand.
10. WATER-IN-FUEL (WIF) SENSOR REPLACEMENT: The combination fuel drain valve/WIF sensor (6) is located on the bottom of the fuel filter housing.
The WIF sensor is not a separately serviceable item. If diagnostics have led you to replace this sensor, then the whole fuel filter assembly needs to be changed.
11. FUEL HEATER ELEMENT REPLACEMENT: The fuel heater element (1) is located in the fuel filter housing (8). To replace heater, the entire housing assembly must be replaced. 12. Drain fuel filter. See previous steps.
13. Disconnect electrical connectors (2), (3) and (4).
14. Disconnect quick-connect fittings (1), (2) and (4) at housing. 15. Remove housing mounting nuts (3). 16. Remove housing assembly.
17. FUEL TEMPERATURE SENSOR REPLACEMENT: The fuel temperature sensor (5) is located in the fuel filter housing (8). To replace sensor, the entire housing assembly must be replaced. 18. Drain fuel filter. See previous steps. 19. Disconnect electrical connectors (2), (3) and (4).
 20.   Disconnect quick-connect fittings (1), (2) and (4) at housing.
 21.   Remove housing mounting nuts (3).
 22.   Remove housing assembly.
 23.   DRAIN VALVE REPLACEMENT: The Drain Valve is located on the bottom of the fuel filter. This is
not a separately serviceable item. If replacement is necessary, replace the entire filter/filter canister
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FUEL FILTER/WATER SEPARATOR📷 3
Refer to maintenance schedules for recommended fuel filter replacement intervals.
 1.   FUEL FILTER:
 2.   Lubricate new fuel filter O-ring with clean engine oil.
 3.   Position new fuel filter/canister assembly (7) to housing.
 4.   Rotate fuel filter/canister assembly until it comes to a hard stop.
 5.   Tighten the filter element an additional half-inch of rotation.
 6.   Connect WIF sensor electrical connector (4).
 7.   Be sure drain valve (6) is tight.
 8.   FUEL HEATER ELEMENT OR FUEL TEMPERATURE SENSOR:
Both the fuel heater element and fuel temperature sensor are attached to the fuel filter housing. To replace either of these components, the entire housing assembly must be replaced.
9. Position housing/canister assembly to body.
10. Install housing mounting nuts (3). 11. Connect quick-connect fittings (1), (2) and (4) to housing fittings.
12. Connect electrical connectors (2), (3) and (4). 13. WATER-IN-FUEL (WIF) SENSOR REPLACEMENT: The combination fuel drain valve/WIF sensor is located on the bottom of the fuel filter housing.
The WIF sensor is not a separately serviceable item. If diagnostics have led you to replace this sensor, then the whole fuel filter assembly needs to be changed.
SENSOR-WATER IN FUEL
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