Diesel Fuel System - Water In Fuel Lamp ON

Article No.
04-9-2

05/11/04

^ DRIVEABILITY - WATER-IN-FUEL LAMP
ILLUMINATED AFTER DRAINING HEATED FUEL
CONDITIONING MODULE (HFCM) - VEHICLES BUILT
PRIOR TO 11/1/2003 - 6.0L ENGINE

^ ENGINE - FUEL SYSTEM-WATER-IN-FUEL LAMP
ILLUMINATED AFTER DRAINING HEATED FUEL
CONDITIONING MODULE (HFCM) - VEHICLES BUILT
PRIOR TO 11/1/2003 - 6.0L ENGINE

FORD:
2003-2004 EXCURSION, F SUPER DUTY

ISSUE
Some 2003-2004 Super Duty/Excursion vehicles built prior to 11/1/2003 equipped with the 6.0L Powerstroke, may exhibit a water-in-fuel (WIF) lamp illuminated. The lamp does not turn off after water has been drained from the horizontal fuel conditioning module (HFCM). This may be due to corrosion/sediment build up in the water reservoir. This build up may also cause the drain plug to stick making drain plug removal difficult.

ACTION
It is not necessary to replace the HFCM. There is a new fuel manifold (3C3Z-9B249-AB) available which will correct the condition. Refer to following Service Procedure.

SERVICE PROCEDURE

WARNING
SMOKING OR OPEN FLAME OF ANY TYPE MUST NOT BE PRESENT WHEN WORKING NEAR FUEL OR FUEL VAPOR.

1. Disconnect both battery ground cables. Refer to Workshop Manual Section 414-01.

2. Raise and support the vehicle. Refer to Workshop Manual Section 100-02.

NOTE
LATE BUILD SHOWN IN WORKSHOP MANUAL, EARLY BUILD SIMILAR.





3. Open the fuel/water separator drain valve to release the fuel pressure (Figure 1).





4. Disconnect the fuel pump, fuel warmer and water-in-fuel electrical connectors from HFCM (Figure 2):

5. Disconnect the fuel hoses from HFCM:





a. Remove the fuel hose retaining clips and discard. Disconnect the fuel hoses from the fuel pump (Figure 3 - # 1).

b. Press in the retaining clips and release the fuel hoses (Figure 3 - # 2).





6. Remove the screws and the old fuel manifold cover (Figure 4).

7. Inspect/clean debris from the HFCM water reservoir housing (max. 25 psi air).





8. Install the new fuel manifold and screws (Figure 5).

9. Reinstall all electrical connectors and fuel lines to the HFCM.

10. Verify that there are no fuel leaks from the HFCM.





Parts Block

OTHER APPLICABLE ARTICLES: NONE

WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage

OPERATION DESCRIPTION TIME

040902A Replace Fuel Manifold 0.7 Hr.
Following Service
Procedure

DEALER CODING
CONDITION
BASIC PART NO. CODE
9B249 42





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