1. The fuel filter kit should include a large primary fuel filter, a smaller secondary fuel filter and one larger O-ring and a smaller O-ring. If you don’t have these replacements, don’t proceed. You will need a 36mm or 1-3/8" socket to remove the HFCM cap. An oil filter removal tool can also work instead of the socket. The end of a 1/2" drive can be used to remove the filter cap on the engine.

2. Stop the vehicle and shut off the engine.



WARNING: The vehicle must be stopped with the engine off when draining

the HFCM. Fuel may ignite if separator is drained while the

engine is running or vehicle is moving.

It helps to park with the vehicles front on a slight incline with wheels chocked and vehicle in park or in gear with parking brake set.

If the vehicle is 4WD, jack up the driver side front axle to lift the front drive shaft for better clearance to the drain plug.

3. Locate the HFCM and place an appropriate container under the drain plug (see illustration).


Suggestion: Use a 3-liter empty soft drink bottle cut off at the shoulder, clean and empty.

4. Remove the drain plug, using a 6mm hex drive, by turning it counterclockwise from above the plug while holding the empty container under the frame just below the plug.



5. Allow the HFCM to drain for approximately 25 seconds or until clean fuel is observed. A very full fuel tank will cause the HFCM to drain fuel until tank is low enough for flow to stop.

HINT: unclip the fuel return line where it is clipped to the frame by the filter. Unclip the same line from the retainer clip about 12" to the rear. Push the line up and out of the way to get more room to work.

6. Remove the fuel filter cap by turning counterclockwise using a 36mm socket and a pivoting head ratchet. A high quality oil filter type wrench will do.





7. Remove and discard the old fuel filter element from the end cap.

8. Carefully clean the mating surfaces.

The engine will not run properly if the fuel filter is not installed in housing.

9. Install the new fuel filter by sliding the filter into the HFCM. Do NOT use the old o-ring. Diesel fuel makes it swell and will leak if reused. Slide a new O-ring into position above the fuel filter end cap threads.

TIP: Place a piece of foil or plastic wrap on the frame to protect against dirt being transferred to the new filter.



10. Screw the fuel end cap, with new filter and O-ring, back into housing. Torque to 25 Nm (19 lbs/ft.).

11.Reinstall the drain plug by turning it clockwise until it is firmly seated. Do NOT over tighten.

12. Verify that the drain plug is closed and sealed, and then remove the container from under the vehicle.

This completes the primary fuel filter change.

13. Secondary Fuel Filter location.

14. Remove fuel filter end cap with a 15/16th inch socket or ½ inch square drive.


15. Remove the filter and the O-ring. Caution: Fuel filter housing is filled with fuel.

16. Remove excess fuel from housing with bubble syringe (that’s the thing that looks like a turkey baster, but don’t use your wife’s unless you get a new one).

17. Insert new secondary fuel filter (small filter in kit) into fuel filter housing.

18. Slide a new O-ring into position just above fuel end cap threads.

Tip: Some people like to fill the filter housing with an additive like Stanadyne Lubricity Formula.

19. Reinstall fuel end cap with new O-ring back onto the filter hosing. Torque end cap to 14Nm (about 8 lbs./ft.).

Warning: Tightening beyond torque specs will crack the fuel filter cap.

20. Turn ignition key to “ON” DO NOT START ENGINE three times for 30 seconds each with a wait of 15 seconds in between. This will charge the fuel system and move fuel through the pump.

21. Remove all tools and rags clear of engine. Remove drained fuel away from vehicle and properly dispose.

22. Start engine and check for leaks and correct running.