Alliance/Racor

4700 mm 47.02.001

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

  1. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires and 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 jurisdictions 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: Diesel fuel is flammable and can ignite if exposed to an open flame, intense heat, or other ignition source. Do not drain fuel near, or expose fuel vapor to open flame or intense heat. Exposure to open flame or intense heat could start a fire, possibly resulting in personal injury or property damage. When working on a fuel system, have a fire extinguisher within easy reach.

  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, Fuel/Water Separator Assembly, Alliance/Racor

  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 Checking and Replacement
Document Number: 0000121065
Manual Publication Date: 2024-05-23
Topic Publication Date: 2024-10-31