Racor Fuel Filter Install

2005 Jeep Liberty CRD

Total time: 4 hours

This is a very easy upgrade that looks more intimidating than it is.

Parts List

(A)

(A1)

Filter Head + Filter + Bowl +
Heater

Racor 245R122  Good description of how to read Racor part numbers here.

$142.67 from B-Line (includes one 2 -micron filter and 200W/12V heater).

(B)
Water in Fuel (WIF) sensor

Racor RK 30964 (Parker Racor REPL. KIT, WIF SENSOR/CONN. ASSY )
$27.31 from National Fleet Parts

[Thanks to aandlwoods who found this at B-line for $22.22]

(C)
Temp. Sensor

Omega TH-44004-1/4NPT-80

$61 from omega .com

(D)
Connector

FCI Apex 2-way connector from NTI. $25 minimum order.

Can order with a credit card, but requires a shipping account. (Easy to set one up at UPS.com).

(E)

Fitting X 2

90° 1/4" NPT to 3/8" barb. Napa Auto Parts
(F)
Fitting X 1
3/8" to 3/8" splice. Napa Auto Parts
G)
Fuel Line
1ft of 3/8" fuel line. Napa Auto Parts
(H)
Clamp X 4
EFI fuel line clamps from Napa Auto Parts. Use this type instead of common style clamps that can damage the fuel hose.

Step 1: Remove Electrical Connectors

I had plugged the fuel heater connector with epoxy putty to stop the fuel leaking through the connector.

Step 2: Remove Fuel Lines

Step 3: Unbolt Filter Head

Step 4: Remove Unit & Disconnect WIF

Step 5: Remove & Reuse Heater Puck (Optional)

If you don't want to buy the Omega temperature sensor or you are waiting to get one, you can remove the heater "puck," plug the temp sensor wire back into the puck and zip-tie it under the hood.

The bolt is held in with considerable thread sealant and requires a lot of torque to remove.

 

This photo shows the puck zip-tied to my Provent line.

Step 6: Replace Heater Connector

 

Bottom view of filter bowl showing (clockwise from lower left) drain valve, heater connector, user-installed, connector for water-in-fuel (WIF) sensor.

The original CRD layout has the heater on top, but there is plenty of cable length to reach underneath, so I spliced in the Racor heater connection at the same length as the existing one.

Step 7: Replace Temperature Sensor

The temp sensor comes without a connector. I located a vendor (NTI) for the FCI Apex 2.8mm, weather tight connectors used elsewhere on the vehicle.

However, the Omega sensor comes with an 80" wire in a braided, stainless steel jacket. You can custom order the length, and I recommend doing so. But if not here's how I trimmed it.

1. Run one side of the wire along a hacksaw blade until...

2 ...you reveal the white inner sleeve.

3. Then using some small tool (I used an electrical connector pick), extend the opening until you can put the tool between the wire and the jacket. Now you can clip off the jacket and strip the wire. You can see in the photo that I've torn the sleeve revealing a wire.

 

 

With a weather tight connector you have to remember to put everything on the wire BEFORE you solder.

IMPORTANT: READ THE INSTRUCTIONS PRIOR TO ASSEMBLING OR DISASSEMBLING A WEATHER-TIGHT CONNECTOR. IT IS NOT AS EASY AS IT SEEMS.

Note that I put the jacketed wire through only one side of the connector instead of splitting it outside. This provides a seal and some strain relief. A dummy plugs the unused hole.

 

Step 8: Replace WIF connector

As the photo reveals, the original CRD WIF unit differs in physical form. It also seems to use different threading..

I tested the Racor before installing it by immersing it in a tub of water. Presto! My dashboard WIF indicator lights up.

 

As with the heater, this was spliced in at the same length as the original WIF.

Red = Heater
Blue = WIF
Orange = Old temp sensor (replaced after filter installed to gauge length).

Step 9: Extend Fuel-in Line

At first I set this up like EurekaBoy, using the existing fuel-in hose. But this put some strain on the metal fuel line and the old hose had some seepage at the old clamp location. So I spliced in a few inches of new hose.

I would splice farther in toward the firewall than I did to allow for more of a smooth curve to the inlet fitting.

 

Step 10: Install Racor

I used teflon tape on the NPT fittings, but I later read that Racor discourages its use as they claim small bits could break loose.

Step 11: Connect Fuel Lines

The location of the Racor inlet is front and center.

I trimmed an inch or two of the outlet hose. This fit better and trimmed away the old clamp location.

Step 12: Prime and go