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Air in Fuel Fix  RSS feed
Forum Index » Recommended Mods for Longevity
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GreenDieselEngineering
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Joined: 10/07/2009 07:25:47
Messages: 348
Location: Southeast Michigan
The KJ CRD has been plagued with air-in-fuel issues that can cause difficult starting, limp-home situations, stall-outs and sometimes a CEL. P0093 is the most common error code, but P0087 is also possible. The most common root cause for air-in-fuel is a melted connector around the terminals for the fuel heater. This connector is located on the fuel/water separator head assembly. There are two connectors, the heater is the one closest to the driver's side. An easy check is to remove the connector by pressing down on the retention tab and pulling. Then press the fuel primer on the head assembly until it becomes hard to press. Use a light to look inside the heater connector on the head to see if fuel or air is seeping out around the terminals. If evidence of leakage is found a new upgraded fuel head assembly is highly recommended! Over time the air leak will get worse and air can cause premature failure of the Bosch fuel pump inlet metering unit...this is when the solution can get very expensive!

Mopar sells an upgraded fuel/water separator assembly that incorporates a larger heater connector and bigger terminals that are properly sized for the current draw (no heat buildup). The assembly also requires an electrical jumper harness with the new mating connector. The original needs to be cut off and the two exposed wires soldered to the new connector.

Fuel/water separator assembly (with new filter) 68043089AA $76.20

Wire harness kit 68043086AA $10.75

The installation is very straight forward and only takes 10-20 minutes. There are two nuts holding the assembly to the firewall (remove these first), then remove the three electrical connectors on the assembly (3rd one on bottom of filter), loosen clamps on fuel supply lines and remove. Then install new unit and re-assemble.

This mod is a good preventative measure and is a good starting point for anyone currently facing air in fuel issues. There are other potential leak paths in the fuel system, but this one is the issue for the vast majority.

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AZCRDGuy

Joined: 18/04/2010 11:58:32
Messages: 2
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How long have the new harness and separator assembly been available?

Curious to know if my CRD already has them. Are they labeled with the part numbers you mention below?

stoutdog

Joined: 19/07/2009 14:25:03
Messages: 11
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AZCRDGuy wrote:How long have the new harness and separator assembly been available?

Curious to know if my CRD already has them. Are they labeled with the part numbers you mention below?


Don't know how long, but there's any easy way to check for the new wiring harness. It should be obviously spliced in and have a blue connector (I think the original was black). The connector should also be about as wide as the one next to it, whereas the original was about 1/2 the width.
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