Manifold Cover / WIF Sensor Installation/Inspection Procedure.




<TABLE border=0 itxtvisited="1"><TBODY itxtvisited="1"><TR itxtvisited="1"><TD itxtvisited="1"></TD><TD width=100 itxtvisited="1">CAUTION:</TD><TD itxtvisited="1">SMOKING OR AN OPEN FLAME OF ANY TYPE IS PROHIBITED WHEN WORKING NEAR FUEL OR FUEL VAPOR.</TD></TR></TBODY></TABLE>

1. <LI itxtvisited="1">Disconnect both battery ground cables. Refer to Workshop Manual, Section 414-01. <LI itxtvisited="1">Raise and support the vehicle. Refer to Workshop Manual, Section 100-02. <LI itxtvisited="1">Open the fuel/water separator drain plug to release contents (Figure 1).
   
   
   Figure 1 - Article 06-6-5
   
   
   <LI itxtvisited="1">Disconnect the fuel pump, heater, water in fuel electrical connectors from HFCM (Figure 2).
   
   
   Figure 2 - Article 06-6-5
   
   
   <LI itxtvisited="1">Disconnect HFCM electrical harness from main vehicle harness. <LI itxtvisited="1">Disconnect the fuel hoses from HFCM.
   1. <LI itxtvisited="1">Remove the fuel hose retaining clips and discard. Disconnect the fuel hoses closest to the engine (Figure 3 number 1).
      
      
      Figure 3 - Article 06-6-5
      
   2. Press in the retaining clips and release the fuel hoses closest to the fuel <NOBR style="COLOR: darkgreen; FONT-SIZE: 100%; FONT-WEIGHT: normal" id=itxt_nobr_25_0>tank</NOBR> (Figure 3 number 2).
   <LI itxtvisited="1">Remove the screws and the old fuel manifold cover (Figure 4).
   
   
   Figure 4 - Article 06-6-5
   
   
   <LI itxtvisited="1">Inspect/clean debris from the HFCM water reservoir housing (max. 25 psi air). <LI itxtvisited="1">Install the new manifold and screws and torque to 44 lb-in (5 N-m) (Figure 5).
   
   
   Figure 5 - Article 06-6-5
   
   
   <LI itxtvisited="1">Install the new electrical harness and reconnect/reinstall fuel lines. Electrical harness will have connectors for the pump, for the water in fuel sensor, and one that connects to the main vehicle harness. <LI itxtvisited="1">Verify that there are no fuel leaks from the HFCM.
2. Remove and discard heater 30 amp (J-case style) heater fuse.
   1. For 2003-2004 Model Years, remove 30 amp Fuse F2.105 located in Central Junction Box (CJB). Refer to 2003 or 2004 Ford F-Super Duty (F250/350) Wiring Diagrams (EVTM), Section 11 (pages 1-3).
   2. For 2005 Model Year, remove 30 amp Fuse F1.7 located in the engine Battery Junction Box (BJB). Refer to 2005 Ford F-Super Duty (F250/350) Wiring Diagrams, Section 11 (pages 4-5).
      <TABLE border=0 itxtvisited="1"><TBODY itxtvisited="1"><TR itxtvisited="1"><TD width=80 itxtvisited="1">NOTE:</TD><TD itxtvisited="1">DO NOT REINSTALL HEATER FUSE (FUSE IS NOT REQUIRED WITH NEW HFCM MANIFOLD).</TD></TR></TBODY></TABLE>

<TABLE border=1 cellSpacing=0 cellPadding=3 itxtvisited="1"><TBODY itxtvisited="1"><TR itxtvisited="1"><TH align=middle itxtvisited="1">PART NUMBER</TH><TH align=middle itxtvisited="1">PART NAME</TH></TR><TR itxtvisited="1"><TD class=NOBOTTOMBORDER align=left itxtvisited="1">6C3Z-9B249-B</TD><TD class=NOBOTTOMBORDER align=left itxtvisited="1">HFCM Kit</TD></TR></TBODY></TABLE>