Fulltext TSBs

Technical Service Bulletins

TSB
06-6-5
  • WATER-IN-FUEL (WIF) LAMP ON
Publication Date: March 10, 2006

FORD:
2003-2005 Excursion, F-Super Duty
2004-2005 E-Series

This article supersedes TSB 06-3-10 to update the part number listed in Step 2(b) of the Service Procedure.

ISSUE:

  • Some 2003-2005 F-Super Duty vehicles built prior to 9/22/2004, 2003-2005 Excursion vehicles built prior to 1/10/2005, and 2004-2005 E-Series vehicles built prior to 9/16/2004, equipped with a 6.0L diesel engine, may exhibit an intermittent/flickering water-in-fuel (WIF) lamp. The intermittent condition may be more prominent while turning corners, braking, or during uphill/downhill driving
  • Some 2003-2005 F-Super Duty and Excursion vehicles may exhibit a continuous WIF lamp on, even without the presence of water, due to debris in the reservoir or corrosion on the WIF sensor pins located in the manifold
  • Some 2003-2005 F-Super Duty and Excursion vehicles may exhibit both intermittent/flickering and continuous WIF due to corrosion and the lack of new calibration

ACTION:

Use the following Service Procedure based upon the customers symptom.

SERVICE PROCEDURE

  1. For intermittent/flickering WIF lamp condition reprogram the powertrain control module (PCM) to the latest calibration using the WDS release B32.11 or higher. Calibration files may also be obtained at www.motorcraft.com.
  2. If the WIF lamp continuously illuminates without the presence of water, this may be due to corrosion on the sensor pins or sediment build up in the water reservoir.
    1. Remove the horizontal fuel conditioning module (HFCM) following the Manifold Cover / WIF Sensor Installation/Inspection Procedure and inspect for corrosion on the pins or significant sediment in the reservoir. If there is corrosion/sediment on the pins, proceed to Step b. If there is not refer to online Powertrain Controls/Emissions Diagnosis (PC/ED) lead diagnostics and do not proceed with the TSB. The online PC/ED was updated on 2/27/2006.
    2. If corrosion on the pins is causing the WIF lamp to illuminate, clean the housing of the HFCM of any debris and replace the manifold cover / WIF sensor with Service Part 6C3Z-9B249-B following the Manifold Cover / WIF Sensor Installation/Inspection Procedure. It is not necessary to replace the entire HFCM assembly.

      NOTE:THE HFCM HEATER IS NOT REQUIRED FOR 2003 THRU 2005 EXCURSION AND 2003 THRU 2006 F-SERIES VEHICLES SO THE HEATER WAS REMOVED FROM THE MANIFOLD/SENSOR SERVICE KIT, AND THE HEATER PIGTAIL WAS REMOVED FROM THE JUMPER WIRE HARNESS WHICH IS INCLUDED IN THE MANIFOLD/SENSOR SERVICE KIT.

  3. Vehicles with both an intermittent and continuous WIF light due to corrosion are to follow actions 1 and 2 as described above, referring to the vehicle built dates and application.

Manifold Cover / WIF Sensor Installation/Inspection Procedure.

CAUTION:SMOKING OR AN OPEN FLAME OF ANY TYPE IS PROHIBITED 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.
  3. Open the fuel/water separator drain plug to release contents (Figure 1).


    Figure 1 – Article 06-6-5

  4. Disconnect the fuel pump, heater, water in fuel electrical connectors from HFCM (Figure 2).


    Figure 2 – Article 06-6-5

  5. Disconnect HFCM electrical harness from main vehicle harness.
  6. Disconnect the fuel hoses from HFCM.
    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 tank (Figure 3 number 2).
  7. Remove the screws and the old fuel manifold cover (Figure 4).


    Figure 4 – Article 06-6-5

  8. Inspect/clean debris from the HFCM water reservoir housing (max. 25 psi air).
  9. Install the new manifold and screws and torque to 44 lb-in (5 N-m) (Figure 5).


    Figure 5 – Article 06-6-5

  10. 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.
  11. Verify that there are no fuel leaks from the HFCM.
  12. 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).

      NOTE:DO NOT REINSTALL HEATER FUSE (FUSE IS NOT REQUIRED WITH NEW HFCM MANIFOLD).


PART NUMBERPART NAME
6C3Z-9B249-BHFCM Kit

WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage

OPERATIONDESCRIPTIONTIME
060605A2003-2005 Excursion/F-Super Duty And 2004-2005 E-Series: Reprogram The Powertrain Control Module (Do Not Use With 12650D, 12650D84, Or 9249A)0.7 Hr.
060605B2003-2005 Excursion/F-Super Duty: Inspect Pins For Corrosion, Clean The HFCM And Replace The Manifold Cover/WIF Sensor (Do Not Use With 12650D, 12650D84, Or 9249A)0.8 Hr.
060605C2003-2005 Excursion/F-Super Duty: Inspect Pins For Corrosion, Clean The HFCM, Replace The Manifold Cover/WIF Sensor, And Reprogram The Powertrain Control Module (Do Not Use With 12650D, 12650D84, Or 9249A)1.3 Hrs.
MT060605Claim Additional Labor Required As Actual Time Or Use SLTS Operation If AvailableActual Time

DEALER CODING

BASIC PART NO.CONDITION CODE
9B24942