Alliance/Racor

sd mm 47.02.001

The only maintenance necessary on an Alliance or Racor fuel/water separator is to replace the filter element.

  1. Shut down the engine, apply the parking brakes, and chock the tires. Open the hood.
  2. Place a suitable container under the fuel/water separator.

    3. Important: When draining fluid from a fuel/water separator, drain the fluid into an appropriate container, and dispose of it properly. Many states now issue fines for draining fuel/water separators onto the ground.

  3. Turn the drain plug counterclockwise to open it.
  4. When the fuel/water separator is completely drained, turn the drain plug clockwise to close it.

    5. Warning: Do not expose the fuel to open fire. Do not work with the fuel system near open flame or intense heat. To do so could cause fire, possibly resulting in serious personal injury or property damage.

  5. Disconnect the wiring harnesses from the water-in-fuel sensor and, if equipped, the heater. See Fig..

    1. Primer Pump

    2. Mounting Head

    3. O-Ring

    4. Filter Element

    5. Sight Bowl

    6. Water-in-Fuel Sensor

    7. Wiring Harness, Water-in-Fuel Sensor

    8. Wiring Harness, Heater

    9. Drain Plug

    Fig. 1, Alliance Fuel/Water Separator Assembly

  6. Spin off the sight bowl and the filter element as a unit. Remove the O-ring from the top of the filter element.
  7. Remove the sight bowl from the filter element. Clean the O-ring seating surface.
  8. Apply a thin coating of clean diesel fuel or engine oil to the O-rings.
  9. Spin the sight bowl onto the new filter element and then fill the filter element and sight bowl assembly with clean diesel fuel.
  10. Spin the entire assembly onto the mounting head and tighten by hand until snug.
  11. Connect the wiring harnesses for the water-in-fuel sensor and, if equipped, the heater.
  12. Prime the fuel/water separator, as follows.

    If equipped with a primer pump, operate the primer pump until fuel comes out at the drain.

    If not equipped with a primer pump, fill the filter element and sight bowl with clean fuel and crank the engine until it starts.

  13. Start the engine and check for leaks.
  14. Shut down the engine and repair any leaks.
Note:
Parent topic: Fuel/Water Separator Element Check and Replacement
Document Number: 0000120180
Manual Publication Date: 2024-05-23
Topic Publication Date: 2024-11-06