Water-In-Fuel Sensor...

tworock · **Posted:** Thu Jun 09, 2011 2:36 pm

Driving along a couple of days ago and water in fuel sensor lights up. I've read up on all of the fuel head, fuel filter/water separator issues here on the forum. Brought the care to the dealer (under extended warranty.)

Service guy telling me I need a new water in fuel sensor. Does this sound correct to other members?

Is the sensor included on the new water separator?

nickademus · **Joined:** Mon May 09, 2011 2:15 pm **Posts:** 54

filter and wif sensor are included on the new style seperator.

tworock · **Posted:** Thu Jun 09, 2011 3:09 pm

So, the service writer would be incorrect if he's telling me he's replacing only the sensor itself?

(another thing while I'm thinking about it. It's time to change the fuel filter. Do I need to remind the service people to remove the o-rings from the old filter and re-use them on the new?)

papaindigo · **Posted:** Thu Jun 09, 2011 3:18 pm

I won't say it's completely bogus but frankly I've never heard of the sensor going bad. It's a relatively "dumb" part with zero moving pieces; just a wire plug in and 2 posts inside the filter such that if water is present enough current passes across the 2 posts to trigger the water in fuel light. There may be other ways to test it but seems to me one way would be to pour some clean diesel in a cup; stick the inside tip of the sensor in the fuel; if the water in fuel light does not come on sensor is likely ok; one could double check with water in the cup and if the light does come on the sensor is fine. I'd be curious how they decided the sensor needed replacing. On the older, at least, Cummins filters there was a valve and a tube associated with this sensor so you could drain filter fluid from the bottom of the filter into a container and visually inspect for water. That's not possible on the CRD filter as there is no valve. Perhaps one could remove the filter from the vehicle with the sensor in place and without draining the filter; then pull the senor out over a container so as to drain the filter from the bottom and then inspect for water. Under NO circumstances would I believe anyone who said well we took the filter off and poured it out from the top and saw no water so the sensor must be bad; these filters don't pour out well that way and there is a large chance water is still present.

For what it's worth the list price for the sensor, Mopar or Airtex is all of about $20 (Mopar part 5143002AA) so the cost of the part is no big deal. New after market filters do not come with a new sensor. I don't know if Mopar ones do but I doubt it. The exception is if you order a new 2n gen fuel head, if this is what you mean by separator, it comes with a Mopar filter installed WITH a sensor. I've been recommending that folks who get the new head save their old sensor just in case but them I'm a parts pack rat.

No you don't reuse the seals on the old filter but they do need to be sure both seals come off when they remove the old filter.

tworock · **Posted:** Thu Jun 09, 2011 4:15 pm

Apparently, this is how this issue (water in fuel light) will be resolved.

New water in fuel sensor ($100.00 cost per extended warranty.)

New fuel filter ($149.00 - needed as truck has 51,000 miles - regular maintenance.)

Plus tax.

Does anybody know the cost of the new fuel head/fuel filter/water separator unit that includes everything? Seems that would have been an easier fix and may have saved trouble down the line.

tworock · **Posted:** Thu Jun 09, 2011 7:32 pm

I called another local dealer for a price on the
"Separator Fuel:Water"
just to see what the price was. $125 is what they gave me, but the counterman at the parts dept. couldn't tell from his drawing whether or not it came with the filter and water in fuel sensor. I'll report more when the counter guy gets back to me when I get back in town.

tworock · **Posted:** Thu Jun 09, 2011 7:35 pm

Oh, the part number referenced is #68043089AA

ATXKJ · **Posted:** Thu Jun 09, 2011 8:20 pm

you can get the new filter head With installed filter and new wiring plug for ~ $100 shipped from Mopar Parts America - the only thing that could go bad on the sensor would be the wires shorted together - check and see if they're twisted.

but going to the dealership - those are typical prices.

papaindigo · **Posted:** Fri Jun 10, 2011 7:58 am

tworock - parts prices - WIX fuel filter without sensor ca. $30 NAPA; sensor ca. $20 dealer or mail order; 2nd gen fuel head which comes with new fuel filter AND sensor installed plus the required wiring/heater plug pigtail ca. $125 shipped if you shop around. See http://www.greendieselengineering.com/f ... st/76.page on why you need the 2n gen head and how to tell if you already have it.

If you have a 1s gen head pull the heater plug and check for a diesel leak. If present the dealer needs to warranty replace the head assembly and pigtail or replace it under TSB 18-011-09 APR 09.

Recommendations - if you have a 1st gen head either DYI the 2n gen head or have the dealer do it. If you do the latter and they don't warranty or TSB it be sure you only get charged for the head unit and wiring pigtail NO separate fuel filter or sensor charge as they both come with the head unit. If you already have the 2n gen head I'd either DYI a fuel filter change or have the dealer do it WITHOUT replacing the senor. My personal bet is, absent the wiring issue ATXKJ mentions, the sensor is just fine but your old filter has trapped water. If that's the case replacing it with a new filter should make the warning light go out. If not then and only then you might have a bad sensor and replacing that can be done with the new filter on the vehicle.

Water-In-Fuel Sensor...

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