DD15 Engine

Section 35.10 Fuel Filter Module

Section 35.10
Fuel Filter Module

The fuel filter module is located on the left side of the engine block. The fuel filter module separates out the water in the fuel and filters out dirt particles in two stages. ‪

Section 35.10.1
Removal of Fuel Filter Module

Remove as follows:‪

  1. Drain the coolant.
  2. Disconnect and remove the coolant lines from the front and bottom of the module.
  3. Drain fuel filter module by using air pressure.
  4. Disconnect fuel feed and return lines (to tank) from the fuel filter module.
  5. Disconnect remaining fuel lines.
  6. Disconnect electrical connectors from sensors.
  7. Remove line assemblies from high pressure fuel pump.
  8. Remove the four bolts securing the fuel filter module to the cylinder block and remove fuel filter module from engine block.
  9. Remove the fuel cooler O-ring seal from the engine block and discard.

Section 35.10.2
Disassembly of the Fuel Filter Module

Disassemble as follows:‪

  1. Remove the fuel cooler from the fuel filter module.
  2. Remove the three filter covers using a 36 mm socket.
  3. Pull the covers and filters straight up and out of the fuel filter module.
  4. Remove the filters from the covers by applying a lateral force to the bottom of the filters. The filter will unsnap from the cover. Discard the filters.
  5. Remove the seal rings from the covers and discard seal.
  6. Inspect the fuel filter module for cracks or damage ; replace if necessary.
  7. Inspect fuel filter sensors; replace if necessary.
  8. Inspect the fuel cooler for wear or damage; replace if necessary.
  9. Inspect the fuel filter housing and cooler for debris and clean if necessary.

Section 35.10.3
Assembly of the Fuel Filter Module

Assemble as follows:‪

  1. Install new seal rings onto plastic caps and coat with clean engine oil.
  2. Install the filters into the plastic caps by snapping the filter into the cap.

    Note: The prefilter has slots and the tabs should align with the slot in the plastic cap.

  3. Install filters and caps into fuel filter module
  4. Turn the cap counter clockwise until a clicking sound is made and then turn the cap clockwise and hand tighten.
  5. Torque prefilter cap to 15-20 N·m (11-15 ft·lb).
  6. Torque water separator and fuel filter caps to 50-60 N·m (37-44 ft·lb).
  7. Install fuel cooler into fuel filter module.

Section 35.10.4
Installation of the Fuel Filter Module

Install as follows:‪

  1. Install a new coolant O-rings onto cylinder block.
  2. Install guide studs.
  3. Install fuel filter module using care not to damage coolant O-ring seal between cylinder block and fuel cooler.
  4. Torque mounting bolts to 60 N·m (44 ft·lb).
  5. Connect coolant lines.
  6. Install bolt securing the air compressor coolant line to the fuel filter module and torque to 25 N·m (15 ft·lb).
  7. Fill engine with coolant and pressure test system to check for a seal leak between fuel cooler and cylinder block.
  8. Install fuel lines to fuel filter module and high pressure fuel pump.
  9. Torque fuel lines to 25 N·m (18 ft·lb).
  10. Connect the electrical connectors from sensors.
  11. Prime fuel system and check for leaks. Refer to "6.5 Fuel System Priming" , “Fuel System Priming.”

Section 35.10.5
Removal of Final Filter

Remove the final filter as follows:‪

  1. Using a 36-mm socket, unscrew the final filter cap.

    NOTICE:

    Do not tilt the final filter when removing it from the housing. Possible damage to the final filter or stand pipe may occur.‪

  2. Pull the cap and final filter straight up and allow the fuel to drain back.
  3. Remove the final filter (2) from the plastic cap (1) by placing the filter on a solid surface and apply pressure on the plastic cap at an angle.
    Click to see this graphic in a separate window
  4. Discard the filter.
  5. Inspect inside the housing for any large debris and clean if needed.
  6. Discard plastic cap seal ring.

Section 35.10.6
Installation of the Final Filter

Install the final filter as follows:‪

  1. Snap new final filter into the plastic cap.
  2. Install a new plastic cap seal ring.
  3. Apply a light coat of petroleum-based lithium grease to the cap seal ring (1) and to the lower seal on the final filter.
    Click to see this graphic in a separate window
  4. Install the final filter into the fuel filter module.
  5. Turn the cap counterclockwise until a “click” sound is made, then turn clockwise and hand tighten.
  6. Torque final filter cap to 50-60 N·m (37-44 ft·lb).
  7. Prime fuel system using fuel priming valve or hand primer. Refer to "6.5 Fuel System Priming" , “Fuel System Priming.”
  8. After the engine has started, check for leaks.

Section 35.10.7
Removal of Prefilter

Remove prefilter as follows:‪

  1. Using a 36 mm socket, unscrew the prefilter cap.

    NOTICE:

    Do not tilt the prefilter when removing it from the housing. Possible damage to the prefilter or stand pipe may occur.‪

  2. Pull the cap and prefilter straight up and out of the fuel filter housing.
  3. Remove the prefilter from the plastic cap and discard
  4. Discard the prefilter cap seal ring.

Section 35.10.8
Installation of Prefilter

Install as follows:‪

  1. Snap new prefilter (3) into the plastic cap (1).

    Note: The prefilter should snap into the cap in two positions. The tabs (4) should align with the slot in the plastic cap (2).

    Click to see this graphic in a separate window
  2. Apply a thin coat of petroleum-based lithium grease to the prefilter cap seal ring.
  3. Apply a thin coat of petroleum-based lithium grease to the inside and outside of the prefilter bottom seal.
  4. Install the prefilter into the fuel filter module.
  5. Turn the cap counterclockwise until a “click” sound is made, then turn clockwise and hand tighten.
  6. Torque prefilter cap to 15-20 N·m (11-15 lb·ft).
  7. Prime fuel system using fuel priming valve or hand primer. Refer to "6.5 Fuel System Priming" , “Fuel System Priming.”
  8. After the engine has started, check for leaks.

Section 35.10.9
Removal of the Water Separator/Coalescer

Remove the water separator/coalescer as follows:‪

  1. Using a 36–mm socket, unscrew the coalescer cap.

    NOTICE:

    Do not tilt the coalescer when removing it from the housing. Possible damage to the coalescer or stand pipe may occur.‪

  2. Pull the cap and coalescer straight up and allow the fuel to drain back.
  3. Remove the coalescer (1) from the plastic cap (2) by placing the filter on a solid surface and apply pressure on the plastic cap at an angle.
    Click to see this graphic in a separate window
  4. Discard the filter.
  5. Inspect inside the housing for any large debris and clean it out if needed.
  6. Discard plastic cap seal ring.

Section 35.10.10
Installation of Water Separator/Coalescer

Install as follows:‪

  1. Snap a new coalescer into the plastic cap.
  2. Install a new plastic cap seal ring.
  3. Apply a light coat of petroleum-based lithium grease to the plastic cap seal ring and to the lower seal (1) on the coalescer filter.
    Click to see this graphic in a separate window
  4. Install the coalescer into the fuel filter module.
  5. Turn the cap counterclockwise until a “click” sound is made, then turn clockwise and hand tighten.
  6. Torque coalescer cap to 50-60 N·m (37-44 ft·lb).
  7. Prime fuel system using fuel priming valve or hand primer. Refer to "6.5 Fuel System Priming" , “Fuel System Priming.”
  8. After the engine has started, check for leaks.

Section 35.10.11
Removal of Water-in-Fuel Sensor

The water-in-fuel sensor is located on the left side of the engine mounted on the fuel filter module.‪

Remove as follows:‪

  1. Drain the fuel filter module using the water drain valve located on the bottom on the bottom of the fuel filter module.
  2. Pull gray tab down and disconnect the harness connector from the Water-in-Fuel Sensor.
  3. Remove two screws from sensor and remove sensor.

Section 35.10.12
Installation of the Water-in-Fuel Sensor

Install as follows:‪

  1. Lubricate the seal ring on the new sensor with clean fuel.
  2. Install water in fuel sensor to fuel filter module.
  3. Install two screws to the Water-in-Fuel Sensor and fuel filter module and tighten bolts 9-13 N·m (6.5-9.5 ft·lb).
  4. Install harness connector to sensor and push in the gray tab on the connector to lock harness connector.
  5. Prime fuel system using fuel priming valve or hand primer. Refer to "6.5 Fuel System Priming" , “Fuel System Priming.”

Section 35.10.13
Removal of the Supply Fuel Temperature Sensor

The Supply Fuel Temperature Sensor is located on the left side of the engine on the fuel filter module.‪

Remove as follows:‪

  1. Drain the fuel filter module using the water drain valve located on the bottom of the fuel filter module.
  2. Unseat the secondary lock on the electrical connector.
  3. Push gray tab down and pull harness connector from sensor.
  4. Using the appropriate wrench on the hex end of the fuel temperature sensor unscrew the sensor from the fuel filter module.

Section 35.10.14
Installation of the Supply Fuel Temperature Sensor

Install as follows:‪

  1. Install the sensor and new gasket on the engine and using the appropriate wrench on the hex end of the sensor tighten the sensor. Torque sensor to 35-45 N·m (26-33 lb·ft).
  2. Install harness connector onto sensor and push gray tab to the up position.
  3. Seat secondary lock on the electrical connector.
  4. Prime the fuel system using fuel priming valve or hand primer. Refer to "6.5 Fuel System Priming" , “Fuel System Priming.”

Section 35.10.15
Removal of the Fuel Bowl/Filter Cover

Remove the fuel bowl as follows:‪

  1. Drain the fuel module with the water drain.
  2. Disconnect the Fuel Temperature Sensor connector and the WIF Sensor connector.
  3. Remove the four bolts (1), spacers (2) and O-rings (4) retaining the MCM (3) to the block.
    Click to see this graphic in a separate window
  4. Remove the fuel lines (1, 2) for the MCM (3) cooler at the fuel module (4).
    Click to see this graphic in a separate window
  5. Remove the outer two fuel bowl retaining bolts (1).
  6. From the bottom with a long extension, remove the inside two fuel bowl bolts (2).
    Click to see this graphic in a separate window
  7. Pull down and push side-to-side to remove the bowl from the module.
  8. Rotate the bowl 180 degrees and push it forward and pull it out from under the module.

Section 35.10.16
Installation of the Fuel Bowl/Filter Cover

Install the fuel bowl as follows:‪

  1. Install a new O-ring (1) onto the bowl and lubricate it with lithium grease.
    Click to see this graphic in a separate window
  2. Install the bowl (2) onto the module and start the outer two bolts (3).
  3. Push firmly upward on the bowl until it seats against the module flush all the way around.
  4. Install the inner two bolts (4) and torque them. The torque is 20 N·m (15 lb·ft).
  5. Torque the two outer bolts. The torque is 20 N·m (15 lb·ft).
  6. Install the MCM bolts and torque them. The torque is 34 N·m (25 lb·ft).
  7. Install the fuel lines to the MCM cooler.
  8. Prime the fuel system.
  9. Start and check for leaks.


DD15 Fuel System Technician's Guide - DDC-SVC-MAN-0037
Generated on 10-13-2008

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