Ford Water-in-Fuel Indicator Dampens Driver's Spirit

Ford Water-in-Fuel Indicator Dampens Driver’s Spirit

Some 2003-'04 Ford F Super Duty/Excursion (vehicles with 6.0L Powerstroke engine built prior to Nov. 1, 2003) owners may complain of an illuminated water-in-fuel (WIF) lamp. 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 buildup in the water reservoir. This buildup may also cause the drain plug to stick making drain plug removal difficult.

It’s not necessary to replace the HFCM. There is a new fuel manifold (3C3Z-9B249-AB) available, which will correct the condition.

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.
2. Raise and support the vehicle. figure 1
Note: Illustrations are of late-build models, early-build models are similar but may differ slightly.
3. Open the fuel/water separator drain valve to release the fuel pressure (see Figure 1).
4. Disconnect the fuel pump, fuel warmer and water-in-fuel electrical connectors from HFCM (see Figure 2). 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 (see Figure 3 – #1).
  b. Press in the retaining clips and release the fuel hoses (see Figure 3 – #2). figure 3
  c. Remove the screws and the old fuel manifold cover (see Figure 4).figure 4
6. Inspect/clean any debris from the HFCM water reservoir housing (max. 25 psi air).
7. Install the new fuel manifold and screws (see Figure 5).Figure 5
a. Tighten the screws to 44 in.-lb. (5 Nm).
8. Reinstall all electrical connectors and fuel lines to the HFCM.
9. Verify that there are no fuel leaks from the HFCM.
10. Drive the vehicle to verify your repair.

Courtesy of Ed Dorowski, ALLDATA editor and Jeff Webster, ALLDATA technical writer.

You May Also Like

KYB Promo Rewards Parts Pros

Parts professionals get rewarded for recommending and selling KYB products.

Following up on the “Feeling is Believing” consumer rebate offer, KYB continues its 2023 national promotion schedule with the launch of “Parts Pro Rewards.”

Beginning May 1st, parts professionals will have the opportunity to earn extra cash for selling sets of 4 KYB shocks, struts or mounts on the same invoice, or pairs of Strut-Plus or Truck Plus assemblies on the same invoice. KYB is a shock & strut supplier to new vehicle manufacturers and can be found on some of the most popular new cars, SUVs and trucks. KYB helps engineer how these vehicles perform when new and can help restore or improve their original designed performance.

Transmission Fluid Hydraulics

You need to know how transmission fluid flows inside an automatic transmission.

Limited-Slip Differentials And Diagnostics

A limited-slip differential helps to control the tangential forces.

Seven CV Joint Mistakes You Shouldn’t Make

If a CV joint fails, it rarely fails on its own. Outside factors can damage a joint worse than cutting a boot with a knife.

Simplifying AWD Systems

No matter the manufacturer, there is almost always an all-wheel drive (AWD) option for most platforms.

Other Posts

NAPA Auto Parts Chooses Brembo for Premium Brake Line

New product partnership expands brake parts offering.

Multiple Employee Promotions Set for KYB

Sales, product and marketing teams see new leadership.

FDP to Open New Automotive Friction Plant in Mexico

The plant will expand FDP’s global production capability for highly engineered brake pads and shoes for the automotive industry.

Autoshop Solutions Partners with BlueRecruit

The two are working together to help bring exceptional technicians, mechanics, and service writers to Autoshop customers’ garages.