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moparfl
moparfl, ASE Certified Technician
Category: Dodge
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Experience:  ASE Master Tech Gold level Chrysler Status 30 years dealership exp
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have a 96 12 valve 5.9 need to change fuel filter. It is very

Customer Question

have a 96 12 valve 5.9 need to change fuel filter. It is very hard to see and get my hands on it.Any secrets to make it easier?Does tube in bottom of filter come out first and then unscrew filter?Do you need to fill new filter with fuel before replacing?Guess I need to know step by step procedure. Ron
Submitted: 5 years ago.
Category: Dodge
Expert:  moparfl replied 5 years ago.
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1996 Dodge Truck 3500 4x2 Pickup L6-359 5.9L DSL Turbo

Vehicle Level Engine, Cooling and Exhaust Engine Fuel Filter Service and Repair Fuel Filter Replacement
Fuel Filter Replacement
Notes

Low Pressure Bleed Bolt


The combination water-in-fuel sensor and fuel filter/water separator is screwed onto a metal housing located on the left/rear side of the engine and below the intake manifold.

REMOVAL

  1. Partially drain the filter/separator. Refer to Draining Water from Filter. See: Draining Water From Filter

Drain Valve At Fuel/Water Separator

  1. Remove the drain hose at the drain valve.

Water-in-fuel Sensor

  1. Disconnect the electrical connector from the WIF sensor at the bottom of the filter.
  2. Remove (unscrew) the filter/separator and WIF sensor as one assembly from the filter housing.

Fuel/Water Separator O-Ring

  1. Remove the 0-ring seal from the filter housing.
  2. Drain the filter/separator.

Water-In-Fuel Sensor

  1. Remove the WIF sensor, 0-ring and drain valve assembly from the filter/separator.
  2. Inspect the WIF sensor probes. Clean contaminants from sensor probes if necessary. Replace sensor if probes will not clean up.

INSTALLATION

  1. Install a new 0-ring seal on WIF sensor.
  2. Install WIF sensor/drain valve assembly into new filter/separator. NOTE:If the new fuel filter/water separator is not filled with clean fuel before it is installed, manual air bleeding of the fuel system may be necessary (temporary rough engine running may occur). If necessary, refer to the Air Bleed Procedure for procedures. See: Powertrain Management\Fuel Delivery and Air Induction\Adjustments
  3. Fill filter/separator with clean fuel.
  4. Apply a light film of clean unused engine oil to the filter/separator seal.

Fuel/Water Separator O-Ring

  1. Install a new 0-ring seal to the filter/separator housing.
  2. Install filter/separator to housing. Tighten filter/separator one-half turn after it makes contact with the housing. Tighten by hand only.
  3. Connect electrical connector to WIF sensor.
  4. Connect drain hose to drain valve.

 

 

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