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SUBJECT DATE
Notice Added to Sections Listed Below February 2012

Additions, Revisions, or Updates

Publication Number / Title Platform Section Title Change

DDC-SVC-MAN-0082 Removal of the Bypass

Valve

Removal of the Pressure

Relief Valve

EPA07/10 Removal of the Quantity

Control Valve A Notice is added to these sections.
DD Platform
DDC-SVC-MAN- 0084 Removal of the Water-in-
Fuel Sensor

SPN 97/FMI 15

SPN 97/FMI 16

All information subject to change without notice. 3

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2 Removal of the Bypass Valve

2 Removal of the Bypass Valve

Remove as follows:

NOTICE: Do not over-tighten the water drain valve. Failure to properly tighten the water drain valve may cause
damage to the water drain valve and housing.

1. Steam clean the engine.

2. Drain the fuel filter module by removing one of the fuel filters or by opening the mechanical drain valve (1) on the fuel
filter module.

3. Remove the bypass valve (1).

4 All information subject to change without notice.

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3 Removal of the Pressure Relief Valve

Remove as follows:

NOTICE: Do not use compressed air.

NOTICE: Do not over-tighten the water drain valve. Failure to properly tighten the water drain valve may cause
damage to the water drain valve and housing.

1. Steam clean the engine and high pressure fuel pump.

2. Drain the fuel filter module by removing one of the fuel filters or by opening the mechanical drain valve (1) on the fuel
filter module.

3. Remove the pressure relief valve.

All information subject to change without notice. 5

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4 Removal of the Quantity Control Valve

4 Removal of the Quantity Control Valve

Remove as follows:

NOTICE: Do not over-tighten the water drain valve. Failure to properly tighten the water drain valve may cause
damage to the water drain valve and housing.

1. Steam clean engine and housing on high pressure fuel pump.

2. Drain the fuel filter module by removing one of the fuel filters or by opening the mechanical drain valve (1) on the fuel
filter module.

3. Remove needle return line (2) from high pressure flange.

4. Remove doser supply line (1) from high pressure flange.

5. Remove 3 bolts (3) that secure high pressure flange to high pressure fuel pump. Discard gasket.
6. If equipped with a two-cylinder air compressor, drain coolant and remove the coolant lines to the air compressor.
7. Disconnect electrical connector from quantity control valve.
8. Remove bracket from high pressure fuel pump to block.

6 All information subject to change without notice.

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9. Remove three bolts attaching quantity control valve to high pressure pump.
10. Remove quantity control valve. Ensure that both O-rings are removed from pump housing.

All information subject to change without notice. 7

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5 Removal of the Water-in-Fuel Sensor

5 Removal of the Water-in-Fuel Sensor

Remove as follows:

NOTICE: Do not over-tighten the water drain valve. Failure to properly tighten the water drain valve may cause
damage to the water drain valve and housing.

1. Drain the fuel filter module by removing one of the fuel filters or by opening the mechanical drain valve (1) on the fuel
filter module.

2. Pull the gray tab down and disconnect the electrical harness connector.
3. Remove the two screws from the WIF sensor; remove the WIF sensor.

8 All information subject to change without notice.

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6 SPN 97/FMI 15 - ALL YEARS

This diagnostic is typically Water In Fuel.

NOTICE: Do not over-tighten the water drain valve. Failure to properly tighten the water drain valve may cause
damage to the water drain valve and housing.

1. Drain the fuel filter module by removing one of the fuel filters or by opening the mechanical drain valve (1) on the fuel
filter module.

2. After the water has been drained, hand tighten the drain plug and prime the fuel filter module via hand pump (approximately
50 times).

WARNING: ENGINE EXHAUST (i)(eov34)

To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.

WARNING: PERSONAL INJURY (eov84)

To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface,
parking brake is set, and the wheels are blocked.

3. Clear the fault code, Start the engine and let the engine run for three minutes. Does the fault become active?
a. Yes; repeat steps 1 through 3. If the fault code is still active, Go to step 4.
b. No; using the service routine “FIS Water-In-Fuel,” select the “Reset Values” to clear the water in fuel registers.
Repair complete.
4. Disconnect the Water-In-Fuel (WIF) sensor connector.
5. Turn the ignition ON (key ON, engine OFF).
6. Inspect the sensor harness for bent, spread, or corroded pins.
a. If the pins are bent, spread, or corroded, repair as necessary.
b. If connector shows no signs of damage, Go to step 7.
7. Measure the voltage between pin 1 and 3 on the harness side of the Water-In-Fuel sensor.
a. If the voltage is greater than 11.5 volts, Go to step 8.

All information subject to change without notice. 9

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6 SPN 97/FMI 15 - ALL YEARS

b. If the voltage is less than 11.5 volts, Go to step 9.

8. Measure the voltage between pin 2 and 3 on the harness side of the Water-In-Fuel sensor.
a. If the voltage is between 4.5 and 5 volts, replace the Water-In-Fuel sensor. Refer to section "Removal of the Water-
in-Fuel Sensor"
b. If the voltage is not between 4.5 volts and 5 volts, repair the wire between pin 2 of the harness side of the Water-
In-Fuel sensor and pin 57 of the MCM 120-pin connector.
9. Measure the voltage between pin 1 on the harness side of the Water-In-Fuel sensor and engine ground.
a. If the voltage is less than 11.5 volts, repair the wire between pin 1 of the harness side of the Water-In-Fuel sensor
and pin 71 of the MCM 120-pin connector.
b. If the voltage is greater than 11.5 volts, repair the wire between pin 3 of the harness side of the Water-In-Fuel sensor
and pin 67 of the MCM 120-pin connector.

10 All information subject to change without notice.

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7 SPN 97/FMI 16 - ALL YEARS

This diagnostic is typically the Water-in-Fuel (WIF) Warning - Ignored.

NOTICE: Do not over-tighten the water drain valve. Failure to properly tighten the water drain valve may cause
damage to the water drain valve and housing.

1. Drain the fuel filter module by removing one of the fuel filters or by opening the mechanical drain valve (1) on the fuel
filter module.

2. After the water has been drained, hand-tighten the drain plug and prime the fuel filter module via the hand pump
(approximately 50 times).

WARNING: ENGINE EXHAUST (i)(eov34)

To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.

WARNING: PERSONAL INJURY (eov84)

To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface,
parking brake is set, and the wheels are blocked.

3. Clear the fault code. Start the engine and let the engine run for three minutes. Does the fault become active?
a. Yes; repeat steps 1 - 3. If the fault code is still active, Go to step 4.
b. No; using the service routine “FIS Water-In-Fuel,” select the “Reset Values” to clear the water in fuel registers.
Repair complete.
4. Disconnect the WIF sensor connector.
5. Turn the ignition ON (Key ON, Engine OFF).
6. Inspect the sensor harness for bent, spread, or corroded pins.
a. If the pins are bent, spread, or corroded, repair as necessary.
b. If connector shows no signs of damage, Go to step 7.
7. Measure the voltage between pin 1 and 3 on the harness side of the WIF sensor.
a. If the voltage is greater than 11.5 volts, Go to step 8.

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7 SPN 97/FMI 16 - ALL YEARS

b. b. If the voltage is less than 11.5 volts, Go to step 9.

8. 8. Measure the voltage between pin 2 and 3 on the harness side of the WIF sensor.
a. If the voltage is greater than 4.5 volts, replace the WIF sensor. Refer to section "Removal of the Water-in-Fuel
Sensor"
b. If the voltage is less than 4.5 volts, repair the wire between pin 2 of the harness side of the WIF sensor and pin 57
of the MCM2 120-pin connector.
9. Measure the voltage between pin 1 on the harness side of the WIF sensor and engine ground.
a. If the voltage is greater than 11.5 volts, repair the wire between pin 3 of the harness side of the WIF sensor and pin
67 of the MCM2 120-pin connector.
b. If the voltage is less than 11.5 volts, repair the wire between pin 1 of the harness side of the WIF sensor and pin 71
of the MCM2 120-pin connector.

12 All information subject to change without notice.

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