water in fuel sensor kit - amazon s3...03/08/2016 1050355-1050356 water in fuel sensor kit (i-00369)...

03/08/2016 1050355-1050356 Water in Fuel Sensor Kit (I-00369) 1

BD Engine Brake Inc. Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2

U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295 Phone: 604-853-6096 | Fax: 604-853-8749 | Internet: www.bd-power.com

Water in Fuel Sensor Kit

Fast and Accurate Detection of Water in Diesel Fuel

1050355 Universal Kit For use with BD FlowMax water separator and other universal applications

1050356 2008-2010 Ford 6.4L Power Stroke For use with stock HFCM fuel pump only

NOTE The universal kit 1050355 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.

DOWNLOAD ENHANCED INSTALL MANUALS AT dieselperformance.com




Kit Contents 1050355 – Universal Kit

1500415 1801120

WIF Module Red LED WIF Wiring Kit

Qty: 1 Qty: 1 Qty: 1

1003345 1300337 1300339

WIF LED Decal Mini Fuse Tap ATO Fuse Tap


2-520334-2 1300348 1300349

Flag Terminal 18-22ga Red Posi-Tap 12-18ga Black Posi-Tap


1800060 1300131 395351700S

Hook and Loop tape Tie Wrap (Medium) WIF Sensor

Qty: 2” Qty: 6 Qty: 1




Kit Contents 1050356 – 2008-2010 Ford 6.4L

1500415 1801120 1500412

WIF Module Red LED Ford Sensor Harness


1003345 2-520334-2 1300337

WIF LED Decal Flag Terminal Mini Fuse Tap


1607310 1800060 1300131

Red Wire 18GA Hook and Loop tape Tie Wrap (Medium)

Qty: 96” Qty: Qty: 6




Table of Contents

Kit Contents 1050355 – Universal Kit ........................................................................ 2

Kit Contents 1050356 – 2008-2010 Ford 6.4L .......................................................... 3

Table of Contents...................................................................................................... 4

Introduction ............................................................................................................... 4

Operation .................................................................................................................. 5

Compatibility ............................................................................................................. 5

Tools Required for Installation .................................................................................. 5

Installation – 1050356 Ford Kit ................................................................................. 6

Water in Fuel Sensor Connection .................................................................... 6

LED Installation ................................................................................................ 7

Power Connection ........................................................................................... 7

Installation – 1050355 Universal Kit .......................................................................... 8

Water in Fuel Sensor Connection .................................................................... 8

LED Installation ................................................................................................ 9

Power Connection ........................................................................................... 9

Wiring Diagram ....................................................................................................... 11

Jumper Settings ...................................................................................................... 11

Troubleshooting ...................................................................................................... 12

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.




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




Installation – 1050356 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”.




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.




Installation – 1050355 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”.




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.




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

98-02 Ford 7.3 Fuse 19 – 10A Instrument Cluster Under Dash

03-07 Ford 6.0 Fuse F2.45 – 10A Instrument Cluster Under Dash

08-10 Ford 6.4 Fuse 37 – 10A HVAC Right Side of Dash

11-14 Ford 6.7 Fuse F11 – 10A Instrument Cluster Right Side of Dash

01-04 GM 6.6 Fuse 5 – 10A Ignition Feed Left Side of Dash

05-06 GM 6.6 IGN 0 FUSE – 10A Ignition Feed Left Side of Dash

07-08 GM 6.6 Fuse 46 – 10A Instrument Panel Under Hood

09-14 GM 6.6 Fuse 43 – 10A Instrument Panel Under Hood

88-91 Dodge 5.9 Fuse 12 – 5A Warning Lights Under Dash



99-02 Dodge 5.9 Fuse 17 – 10A Instrument Cluster Under Dash

03-05 Dodge 5.9 Fuse 28 – 10A Instrument Cluster Under Hood

06-09 Dodge 5.9/6.7 Fuse 40 – 20A Switched Run/Acc. Under Hood

10-11 Dodge 6.7 Fuse M48 – 20A Switched Run/Acc. Under Hood

12 Dodge 6.7 Fuse M15 – 20A Ignition Circuit Under Hood

13-14 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.




Wiring Diagram

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.

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.

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.

Red LED

BD WIF Sensor

Ground Switched 12V LED Ground LED Power Sensor 1 Sensor 2 Sensor Ground

BD

MO

DU

LE

Body Ground Standalone Wiring (FlowMax filter or standalone sensors)

Note: “Sensor 2” terminal unused

Posi-Tap Fuse-Tap

Ignition Power

Red Black

Black Red

Blue

Black

Red LED

Factory Wiring

Ground Switched 12V LED Ground LED Power Sensor 1 Sensor 2 Sensor Ground

BD

MO

DU

LE

Ford 6.4L Wiring (For HFCM, wired in parallel with factory sensor)

Note: “Sensor 1” and “Ground” terminal unused

Fuse-Tap

Ignition Power

Red Black

Red

Blue Black

OE WIF Sensor (In HFCM on left frame rail)

Power Sensor

Jumper unused – Highest sensor sensitivity. This is the default setting. (4.8 volt trigger)

Reduced sensor sensitivity. Recommended for Ford 6.4 (4.3 volt trigger)

For use with sensor with internal resistor. (Dodge 6.7 style)




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. WIF LED wiring problem.

BD WIF LED on all the time Drain water separator and dry the sensor probes. Disconnect from sensor to confirm sensor is not faulty or wet. 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.

BD WIF LED does not illuminate Confirm circuit continuity between the “Sensor” and “Sensor Ground” terminals at the module and at the sensor.

BD WIF LED illuminates intermittently 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.

BD WIF LED illuminates in wet weather conditions or after car wash

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.

water in fuel sensor kit - amazon s3...03/08/2016 1050355-1050356 water in fuel sensor kit (i-00369)...

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