Chrysler Full-Size Trucks 1997-2000 Repair Guide

Fuel Filter/Water Separator (Diesel Engines)

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Fig. The fuel filter/water separator is located directly above the starter motor on the left hand side of the engine. The fuel filter element is removed from the housing after all water (if present) has been drained from the assembly-Diesel engines

The fuel filter/water separator protects the fuel injection pump on the diesel-powered vehicles covered in this guide. The fuel filter/water separator is located on the left hand side of the engine, above the starter motor. The fuel filter is located within the fuel filter/water separator housing.

Water should be removed from the system whenever the water-in-fuel warning lamp remains lit.

The procedure for simple maintenance of the fuel filter/water separator is given here. For more detailed procedures for the replacement or service of the assembly, refer "Fuel System".

Removal & Installation




NOTE
Remove all of the water present in the housing assembly before attempting to remove the fuel filter. Follow the procedures for draining the water separator even if the water-in-fuel light is not illuminated. A drain hose is located on the bottom of the housing for convenience.


CAUTION
Fuel lines on diesel equipped vehicles carry diesel fuel under extremely high pressure. This pressure may be as high as 18,000 psi. Use extreme caution when inspecting or performing service on these systems. High-pressure diesel fuel may cause personal injury if contact is made with the skin or eyes.



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Fig. Late model drain valve system showing handle (2) and drain hose (3) on fuel filter/water (4)



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Fig. Earlier model drain valve system components

  1. Drain all the water and diesel fuel from the housing assembly as follows:
    1. Place a drain pan under the drain hose.
    2.  
    3. With the engine OFF , either rotate the valve to "DRAIN" or lift the valve upward (depending on model) until all water and contaminants have been removed and the fluid stream is clear fuel.
    4.  
    5. If the filter is being replaced, drain the housing completely until all water and fuel is removed.
    6.  
    7. After the filter/separator is empty, close the valve handle.
    8.  

  2.  



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Fig. On 1997-99 diesel powered models the canister nut and cap are separate parts . . .



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Fig. . . .on later models, cap and nut are one piece

  1. Remove the fuel filter cap by removing the nut on top of the canister. On late models the "nut" is part of the cap.
  2.  
  3. The fuel filter will be removed with the cap.
  4.  
  5. Inspect the o-rings for cracks, distortion, or any other signs of deterioration. Replace as needed.
  6.  
  7. Clean and inspect the inside of the canister.
  8.  
  9. Install new o-ring(s) as needed.
  10.  
  11. Install the proper filter element in the canister.
  12.  
  13. Fill the canister with clean diesel fuel.
  14.  


NOTE
If the canister is not filled with clean diesel fuel prior to installation, manual air bleeding of the system will be necessary, follow the procedure outlined in "DRIVEABILITY AND EMISSION CONTROLS."

  1. Apply a coating of diesel fuel to all seals.
  2.  
  3. Position the cap to the canister. On 1997-99 models, be sure the locating tabs are properly lined up to avoid breaking the canister or having the drain valve handle contact the throttle linkage.
  4.  
  5. Install the canister cap. On 1997-99 models, install and tighten nut to 10 ft. lbs. (14 Nm). On later models, tighten cap to 25 ft. lbs. (34 Nm).
  6.  
  7. Start engine and check for leaks by holding a piece of cardboard around seal area. Check cardboard for signs of diesel fuel.
  8.  

 
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