Water in Fuel Sensor Kit

Transcription

1 03/08/ Water in Fuel Sensor Kit (I-00369) 1 Water in Fuel Sensor Kit Fast and Accurate Detection of Water in Diesel Fuel Universal Kit For use with BD FlowMax water separator and other universal applications Ford 6.4L Power Stroke For use with stock HFCM fuel pump only NOTE The universal kit is intended to be used with BD FlowMax water seperator filters however it may be used in other applications as long as there is a spot to thread in the WIF sensor in the bottom of the water seperator assembly.

2 03/08/ Water in Fuel Sensor Kit (I-00369) 2 Kit Contents Universal Kit WIF Module Red LED WIF Wiring Kit Qty: 1 Qty: 1 Qty: WIF LED Decal Mini Fuse Tap ATO Fuse Tap Qty: 1 Qty: 1 Qty: Flag Terminal 18-22ga Red Posi-Tap 12-18ga Black Posi-Tap Qty: 1 Qty: 1 Qty: S Hook and Loop tape Tie Wrap (Medium) WIF Sensor Qty: 2 Qty: 6 Qty: 1

3 03/08/ Water in Fuel Sensor Kit (I-00369) 3 Kit Contents Ford 6.4L WIF Module Red LED Ford Sensor Harness Qty: 1 Qty: 1 Qty: WIF LED Decal Flag Terminal Mini Fuse Tap Qty: 1 Qty: 1 Qty: Red Wire 18GA Hook and Loop tape Tie Wrap (Medium) Qty: 96 Qty: Qty: 6

4 03/08/ Water in Fuel Sensor Kit (I-00369) 4 Table of Contents Kit Contents Universal Kit... 2 Kit Contents Ford 6.4L... 3 Table of Contents... 4 Introduction... 4 Operation... 5 Compatibility... 5 Tools Required for Installation... 5 Installation Ford Kit... 6 Water in Fuel Sensor Connection... 6 LED Installation... 7 Power Connection... 7 Installation Universal Kit... 8 Water in Fuel Sensor Connection... 8 LED Installation... 9 Power Connection... 9 Wiring Diagram Jumper Settings Troubleshooting Introduction Contaminated fuel is one of the leading causes of premature fuel injection system failure in diesel engines. High pressure diesel injection systems rely on fuel filtering systems to ensure there is no water or debris present in the fuel supply. When water is separated from the fuel, it is accumulated in the bottom of the filter assembly to await draining. Water in fuel sensors detect the presence of water in the filter assembly and warn the driver of the need to drain the filter assembly. Most diesel vehicles will come equipped with a water-in-fuel detection system; however some vehicle models (Ford 6.4) have reduced the sensitivity of these systems in later model years to prevent possible accidental warnings. This leads to the possibility for damage to occur without the driver even being aware. See YouTube video of a Ford 6.4 on BD Diesels YouTube channel! Additionally, aftermarket water filtration systems will often not be equipped with a water-in-fuel sensor and rely on periodic draining. Some of these filters will have a threaded drain port which is compatible with the universal water in fuel sensor supplied with this kit which will give the driver additional warning of water contamination.

5 03/08/ Water in Fuel Sensor Kit (I-00369) 5 Operation The module included in this kit monitors a water in fuel sensor for the presence of water, and if detected will illuminate the dash mounted red LED included in the kit. The module is highly sensitive to water so it will immediately warn the driver when the sensor is wet. The module will continue to display the WIF warning LED for three seconds after a detected condition to reduce light flickering. When the key is turned on, the module will light up the warning light for three seconds to show that the module is powered and working. If this lamp test does not occur, investigate the related wiring as your WIF warning may not be functional. Compatibility When used as a standalone installation by either disabling the factory sensor or when used in aftermarket filtration systems, the BD Water in Fuel sensor module has no compatibility concerns. When acting as a standalone with the supplied sensor, this module can work in any year and any model of vehicle so long as the sensor can be installed in the water separator. When utilizing a factory sensor rather than the supplied BD water in fuel sensor care must be taken to ensure the jumper inside the module is set correctly for the sensor type. Additionally if piggybacking on existing factory sensor wires the wiring configuration must also match the wiring diagrams as it is slightly different. If the module is connected to a type of sensor other than listed as being compatible it is not possible to guarantee compatibility with that sensor. Contact BD for more information. Tools Required for Installation Wire strippers Wire crimpers Utility knife Pick tool Small screwdrivers 1/4" drill bit and drill Wrench set

6 03/08/ Water in Fuel Sensor Kit (I-00369) 6 Installation Ford Kit Read and familiarize yourself with the entire installation procedure before beginning. Ensure you have the tools required for the job before starting. Remove the knee bolster below the dashboard. Locate a suitable location to mount the BD WIF control module below the dash. It may be secured with zip ties or hook-and-loop tape. Water in Fuel Sensor Connection Below the vehicle, locate the HFCM on the inside frame rail. Disconnect the factory water in fuel (WIF) sensor connector, and reconnect the BD harness to the WIF sensor and to the original wiring. Ensure the connectors are completely dry before assembly or this will trigger the WIF light to come on. Route this wire into the cab through the firewall or parking brake grommet. Under the dash, connect the two WIF sensor wires to the control module. BLACK to Sensor Ground and BLUE to Sensor 2.

7 03/08/ Water in Fuel Sensor Kit (I-00369) 7 LED Installation Drill a 1/4 hole in the dashboard in a visible location for the WIF warning light. Ensure there is sufficient space behind the chosen location for the LED body to fit. Apply the supplied WIF decal to the dashboard around the mounting hole and insert the led through the hole. Route the LED wires to the control module. Install the RED wire to LED Power and the BLACK wire to LED Ground. Power Connection Install the RED wire to the Switched 12V terminal of the module. Route this wire beneath the dash to the passenger side foot well. Crimp on the supplied flag terminal. Remove the plastic panel below the passenger side of the glove box, just above the carpet. This will allow access to the fuse panel. Remove the fuse panel cover and locate fuse 37 (10A for the HVAC). Remove the fuse, install fuse tapper and connect the red wire. Confirm all wiring is complete by comparing to the diagrams at the end of the manual. If desired, the installer can test the sensor by removing the sensor and placing it in water with the ignition turned on. The WIF LED should illuminate immediately. Note If testing this way, ensure the fuel pump is unplugged or the WIF sensor hole is plugged otherwise fuel will pump out from the sensor port.

8 03/08/ Water in Fuel Sensor Kit (I-00369) 8 Installation Universal Kit Read and familiarize yourself with the entire installation procedure before beginning. Ensure you have the tools required for the job before starting. Remove the knee bolster below the dashboard. Locate a suitable location to mount the BD WIF control module below the dash. It may be secured with zip ties or hook-and-loop tape. Water in Fuel Sensor Connection Install the water in fuel sensor wiring harness at the location for the sensor (near the filter assembly) and route the remaining end into the cab of the vehicle through the firewall. Zip tie the wiring to the frame rail or other harnesses along the way. If this kit is being installed with an aftermarket water filtration system (such as a BD FlowMax), install the sensor in the bottom of the water separator and connect the harness to the sensor. Under the dash, connect the two WIF sensor wires to the control module. BLACK to Sensor Ground and BLUE to Sensor 1.

9 03/08/ Water in Fuel Sensor Kit (I-00369) 9 LED Installation Drill a 1/4 hole in the dashboard in a visible location for the WIF warning light. Ensure there is sufficient space behind the chosen location for the LED body to fit. Apply the supplied WIF decal to the dashboard around the mounting hole and insert the led through the hole. Route the LED wires to the control module. Install the RED wire to LED Power and the BLACK wire to LED Ground. Power and Ground Connection Locate a suitable body ground below the dashboard. Remove an existing screw, nut or bolt. Strip the end of the supplied BLACK wire and crimp the ring terminal to it. Install the BLACK wire with ring terminal under the head of the screw, nut or bolt and refasten. Route the BLACK wire to the control module and trim if necessary. Install into the Ground terminal of the module.

10 03/08/ Water in Fuel Sensor Kit (I-00369) 10 Install the RED wire to the Switched 12V terminal of the module. Route this wire to the chosen location to tap for switched power. Connect the other end of the RED wire to any switched ignition power circuit. This connection may be done using one of the supplied Posi-taps or with the fuse tap and flag terminal supplied. Suggested power tap locations for installation: Vehicle Power Source Location Ford 7.3 Fuse 19 10A Instrument Cluster Under Dash Ford 6.0 Fuse F A Instrument Cluster Under Dash Ford 6.4 Fuse 37 10A HVAC Right Side of Dash Ford 6.7 Fuse F11 10A Instrument Cluster Right Side of Dash GM 6.6 Fuse 5 10A Ignition Feed Left Side of Dash GM 6.6 IGN 0 FUSE 10A Ignition Feed Left Side of Dash GM 6.6 Fuse 46 10A Instrument Panel Under Hood GM 6.6 Fuse 43 10A Instrument Panel Under Hood Dodge 5.9 Fuse 12 5A Warning Lights Under Dash Dodge 5.9 Fuse 2 5A Warning Lights Under Dash Dodge 5.9 Fuse 12 15A Warning Lights Under Dash Dodge 5.9 Fuse 17 10A Instrument Cluster Under Dash Dodge 5.9 Fuse 28 10A Instrument Cluster Under Hood Dodge 5.9/6.7 Fuse 40 20A Switched Run/Acc. Under Hood Dodge 6.7 Fuse M48 20A Switched Run/Acc. Under Hood 12 Dodge 6.7 Fuse M15 20A Ignition Circuit Under Hood Dodge 6.7 Fuse F88 10A Instrument Cluster Under Hood Confirm all wiring is complete by comparing to the diagrams on the next page. If desired, the installer can test the sensor by removing the sensor and placing it in water with the ignition turned on. The WIF LED should illuminate immediately. Note If testing this way, ensure the fuel pump is unplugged or the WIF sensor hole is plugged otherwise fuel will pump out from the sensor port.

11 03/08/ Water in Fuel Sensor Kit (I-00369) 11 Wiring Diagram Ignition Power Body Ground Standalone Wiring (FlowMax filter or standalone sensors) Note: Sensor 2 terminal unused Posi-Tap BD WIF Sensor Fuse-Tap Red LED Black Red Black Red Blue Black Ground Switched 12V LED Ground LED Power Sensor 1 Sensor 2 Sensor Ground BD MODULE The wiring configuration for standalone sensor installation utilizes the terminals marked Sensor 1 and Sensor Ground. This is for applications that do not piggy-back with the stock sensor and stock wiring. This would be applicable to installations using a FlowMax pump or other universal installations. Ignition Power Ford 6.4L Wiring (For HFCM, wired in parallel with factory sensor) Note: Sensor 1 and Ground terminal unused OE WIF Sensor (In HFCM on left frame rail) Fuse-Tap Red LED Red Black Red Blue Black Ground Switched 12V LED Ground LED Power Sensor 1 Sensor 2 Sensor Ground BD MODULE Factory Wiring The wiring configuration for the Ford 6.4 trucks that still use the stock HFCM uses terminals Sensor 2 and Sensor Ground. This input is for applications that piggy-back the stock wiring. Set jumper to Reduced for Ford 6.4. Jumper Settings The BD WIF module has jumpers internally to vary the operation. Jumper unused Highest sensor sensitivity. This is the default setting. (4.8 volt trigger) Power Sensor Reduced sensor sensitivity. Recommended for Ford 6.4 (4.3 volt trigger) For use with sensor with internal resistor. (Dodge 6.7 style) Using the input Sensor 1 is for standalone sensor setups, Sensor 2 is for piggyback sensor installations. The jumper setting will change the monitored voltage for both sensor inputs. You do not need to change jumper settings for Sensor 1 or Sensor 2, the module monitors both at all times.

12 03/08/ Water in Fuel Sensor Kit (I-00369) 12 Troubleshooting The BD WIF sensor module has two diagnostic LEDs inside that may be used for troubleshooting purposes. The Power LED will be lit when the module has power or will flash if the sensor circuit appears to be short circuited. The Sensor LED lights up whenever the sensor detects water; this LED will turn on and off instantly which helps in troubleshooting intermittent conditions. The external LED will come on as soon as water is detected and will stay on for a few seconds afterwards also. BD WIF LED does not illuminate momentarily when key turned on Module attached to constant, not switched power. Check Power led in module. No power to the module. Check Power LED in the module. BD WIF LED on all the time WIF LED wiring problem. Drain water separator and dry the sensor probes. Disconnect from sensor to confirm sensor is not faulty or wet. BD WIF LED does not illuminate BD WIF LED illuminates intermittently BD WIF LED illuminates in wet weather conditions or after car wash WIF LED will illuminate if sensor wire is short circuited. It will also light if the jumper is in position 2 and the sensor circuit is open. Confirm circuit continuity between the Sensor and Sensor Ground terminals at the module and at the sensor. Small quantity of water in the water separator causing intermittent sensing condition. Drain separator. Power to WIF module is intermittent, causing key-on lamp check to repeat. Wiring on exterior of vehicle is not completely water proof. Check for connector issues or faulty insulation. Moisture in the wires will cause a WIF condition to be shown.