Water-In-Fuel Sensor - 6.0L Diesel: Installation

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Vehicles with a damaged sensor

Install a new manifold cover seal and clean the seal mating surface.

Fig 1: Locating Manifold Cover Seal
Courtesy of FORD MOTOR CO.
Install the manifold cover and screws.
- Lubricate the manifold cover seal with clean motor oil just before installing the cover.
- Tighten to 5 Nm (44 lb-in).
  
  Fig 2: Locating Manifold Cover And Screws
  Courtesy of FORD MOTOR CO.
Connect the fuel tubes to the fuel conditioning module. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION - GASOLINE AND DIESEL .

Fig 3: Locating Fuel Tubes
Courtesy of FORD MOTOR CO.

All vehicles

NOTE: Make sure the water-in-fuel sensor hole is clean.

Lubricate the water-in-fuel sensor hole and water-in-fuel sensor seal with clean motor oil.

NOTE: The guides on the water-in-fuel sensor should be pointing down.

Fig 4: Locating Water-In-Fuel Sensor

Courtesy of FORD MOTOR CO.

Align the water-in-fuel sensor to the water-in-fuel sensor hole and insert the sensor.
Using a rubber mallet, gently tap the water-in-fuel sensor into place. Pull on the water-in-fuel sensor to verify that it is securely in place.
Connect the water-in-fuel sensor electrical connector.

Fig 5: Locating Water-In-Fuel Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Prime the fuel system by turning the key on 3 times, for 30 seconds each time.
Start the vehicle and idle for one minute while noting engine performance.
If engine is running rough, check for air leaks.
Shut the vehicle off and inspect for fuel leaks.