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sprinkles08, Chrysler/Dodge/Jeep master tech
Category: Dodge
Satisfied Customers: 16659
Experience:  ASE Master and Advanced Certified, Chrysler/Dodge/Jeep Master Certified, Trans and Hybrid Specialist
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2000 dodge: I change the fuel filter

Resolved Question:

How do I change the fuel filter on my 2000 dodge 2500 diesel? Is it very difficult?
Submitted: 6 years ago.
Category: Dodge
Expert:  sprinkles08 replied 6 years ago.

FUEL FILTER/WATER SEPARATOR

Refer to maintenance schedules in Group 0 in this manual for recommended fuel filter replacement intervals.

REMOVAL

Draining water from fuel filter/water separator housing:

The housing drain valve serves two purposes. One is to partially drain filter housing of excess water. The other is to completely drain housing for fuel filter, drain valve, heater element or water-in-fuel sensor replacement.

The filter housing should be drained whenever 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 drain hose is located at bottom of drain valve Place drain pan under drain hose.
  2. With engine not running, pull drain valve handle upward to OPEN (DRAIN) position Hold drain valve open until all water and contaminants have been removed and clean fuel exits drain hose.
  3. If drain valve, fuel heater element or Water-In-Fuel (WIF) sensor is being replaced, drain housing completely. Dispose of mixture in drain pan according to applicable regulations.
  4. After draining operation, push valve handle downward to CLOSE position
  5. Fuel Filter Replacement: The fuel filter is located inside of the fuel filter housing
    1. Unscrew and remove fuel filter cap at top of fuel filter housing To unscrew, attach tool to 6 - sided hex center of cap. Do not attempt to loosen cap at outer edge. The fuel filter cap is designed to remove filter while pulling up on cap.
    2. Remove o-ring from filter cap and discard.
    3. The filter is retained to the cap with a series of locking fingers. Carefully pry back a few of the fingers to unlock filter from cap.
  6. Water-In-Fuel (WIF) Sensor Replacement: The WIF sensor is located on the side of the fuel filter housing
    1. Disconnect electrical connector at sensor
    2. Unscrew sensor from filter housing.
    3. Check condition of o-ring.
    4. Inspect the 2 WIF sensor probes. Carefully clean contaminants from sensor probes with a cloth if necessary. Replace sensor if probes are covered with contaminants and will not clean up.
  7. Fuel Heater Element Replacement: The heater element is located in the fuel filter housing
    1. Remove fuel filter. See previous steps.
    2. Disconnect electrical connector from fuel temperature sensor housing at side of fuel filter housing
    3. Remove 2 temperature sensor housing mounting screws and carefully remove sensor housing from fuel filter housing.
    4. Pry round wiring connector from fuel filter housing and heater element. This connector passes through the fuel filter housing and is plugged directly into the heater element.
    5. Unlock heater element fingers and pry heater element from filter housing.
  8. Drain Valve Replacement: The drain valve is located on the side of the fuel filter housing
    1. Disconnect drain hose at bottom of drain valve.
    2. Remove 4 drain valve mounting screws.
    3. Remove drain valve from filter housing.
    4. Remove 2 drain valve o-rings from filter housing.

INSTALLATION

  1. Thoroughly clean inside of filter housing, filter cap and all related components.
  2. Fuel Filter:
    1. Fill fuel filter housing with clean diesel fuel. If filter housing (canister) is not filled with clean diesel fuel before installation, manual air bleeding of fuel system may be necessary (temporary rough engine running may occur) If necessary, refer to Air Bleed Procedures.
    2. Snap new filter into locking fingers on cap. Hole in filter should face downward.
    3. Install new o-ring to cap.
    4. Apply a light film of clean diesel oil to cap o-ring seal.
    5. Load filter and cap into housing.
    6. Tighten cap to 25 ft. lbs. torque. Do not overtighten cap.
  3. Water-In-Fuel (WIF) Sensor:
    1. Install new o-ring seal to WIF sensor.
    2. Apply a light film of clean diesel oil to o-ring seal.
    3. Install sensor into housing.
    4. Tighten sensor to 2 - 3 N·m (15 - 20 in. lbs.) torque.
    5. Connect electrical connector to WIF sensor.
    6. Install fuel filter. Refer to previous steps.
  4. Fuel Heater Element:
    1. Do not install fuel filter until heater element is installed.
    2. Position heater element into filter housing (fingers downward) Lock fingers into housing.
    3. Install new o-ring to electrical connector (where connector passes through filter housing) Apply a light film of clean diesel oil to o-ring seal. Press this connector into filter housing until it snaps into heater element.
    4. Install temperature sensor housing and 2 mounting screws to fuel filter housing.
    5. Connect electrical connector.
    6. Install fuel filter. Refer to previous steps.
  5. Drain Valve:
    1. Install 2 new o-rings to valve and filter housing.
    2. Apply a light film of clean diesel oil to both seals.
    3. Position valve to filter housing.
    4. Install 4 mounting screws and tighten to 3 - 5 N·m (30 - 40 in. lbs.) torque.
    5. Connect drain hose to drain valve.
    6. Install fuel filter. Refer to previous steps.
  6. Start engine and check for leaks.
sprinkles08, Chrysler/Dodge/Jeep master tech
Category: Dodge
Satisfied Customers: 16659
Experience: ASE Master and Advanced Certified, Chrysler/Dodge/Jeep Master Certified, Trans and Hybrid Specialist
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