Fulltext TSBs

Technical Service Bulletins

TSB
06-22-12
  • WATER-IN-FUEL (WIF) LAMP ON / FLICKERING
Publication Date: October 24, 2006

FORD:
2003-2005 Excursion
2003-2007 F-Super Duty
2004-2005 E-Series

This article supersedes TSB 06-6-5 to update 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 and 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 2003-2007 F-Super Duty and 2003-2005 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 2003-2007 F-Super Duty and 2003-2005 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 IDS 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. Drain the horizontal fuel conditioning module (HFCM) reservoir and look for significant corrosion debris or sediment in the fluid drained from the reservoir. Remove the WIF sensor and inspect for corrosion on the pins. Remove the WIF Senor by first disconnecting the electrical connector, then using channel locks, rotate the WIF sensor at least 45 degrees counterclockwise. If there is corrosion / sediment on the pins, proceed to Step b. If there is not, refer to PC/ED lead diagnostics and do not proceed with the TSB.
    2. If corrosion on the pins is causing the WIF lamp to illuminate, replace the WIF sensor with service kit, following the WIF sensor installation instructions in the kit.
    3. If there was significant corrosion debris or sediment drained from the reservoir, clean the housing of the HFCM of any debris following the HFCM cleaning procedure. It is not necessary to replace the Manifold or HFCM assembly.
  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.

HFCM Cleaning 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. Disconnect the fuel pump, heater, water in fuel electrical connectors from HFCM (Figure 1).


    Figure 1 – Article 06-22-12

  4. Disconnect HFCM electrical harness from main vehicle harness.
  5. Disconnect the fuel hoses from HFCM.
    1. Remove the fuel hose retaining clips and discard. Disconnect the fuel hoses closest to the engine (Figure 2 Number 1).


      Figure 2 – Article 06-22-12

    2. Press in the retaining clips and release the fuel hoses closest to the fuel tank (Figure 3 Number 2).


      Figure 3 – Article 06-22-12

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


    Figure 4 – Article 06-22-12

  7. Clean debris from the HFCM water reservoir housing (max 25 psi air).
  8. Install the manifold cover and screws and torque to 44lb-in (5 N-m) (Figure 5).


    Figure 5 – Article 06-22-12

  9. Reconnect/reinstall fuel lines.
  10. Verify that there are no fuel leaks from the HFCM.

PART NUMBERPART NAME
6C3Z-9C264-AWIF Snsor Kit

WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage

OPERATIONDESCRIPTIONTIME
062212A2003-2007 Super Duty/2003-2005 Excursion 6.0L: Check Diagnostic Trouble Codes And Reprogram The Powertrain Control Module (Do Not Use With 9249A, 6005E, 6005F, 12650D, 12650D84)0.7 Hr.
062212A2004-2005 Econoline 6.0L: Check Diagnostic Trouble Codes And Reprogram The Powertrain Control Module (Do Not Use With 9249A, 6005E, 6005F, 12650D, 12650D84)0.7 Hr.
062212B2003-2007 Super Duty/2003-2005 Excursion 6.0L: Replace The Water In Fuel Sensor (WIF) If Necessary, Includes Time To Disassemble And Clean The Horizontal Fuel Conditioning Module (HFCM), Check Diagnostic Trouble Codes And Reprogram The Powertrain Control Module (Do Not Use With 9249A, 6005E, 6005F, 12650D, 12650D84)1.3 Hrs.
062212C2003-2007 Super Duty/2003-2005 Excursion 6.0L: Replace The Water In Fuel Sensor (WIF), Check Diagnostic Trouble Codes And Reprogram The Powertrain Control Module (Do Not Use With 9249A, 6005E, 6005F, 12650D, 12650D84)1.0 Hr.
062212D2003-2007 Super Duty/2003-2005 Excursion 6.0L: Replace The Water In Fuel Sensor (WIF) (Do Not Use With 9249A, 6005E, 6005F, 12650D, 12650D84)0.5 Hr.
062212E2003-2007 Super Duty/2003-2005 Excursion 6.0L: Disassemble And Clean The Horizontal Fuel Conditioning Module (HFCM) (Do Not Use With 9249A, 6005E, 6005F, 12650D, 12650D84)0.8 Hr.

DEALER CODING

BASIC PART NO.CONDITION CODE
9B24949

NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article. The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates. The most recent information is available through Ford Motor Company’s on-line technical resources.

Copyright © 2006 Ford Motor Company