Fig.1 Get yourself some good #202 O-rings (1/4" I.D.- 1/8" cross-section), preferably Viton as it holds up to diesel and temp changes very well. The ones pictured here are brown colored, but they can be black- same material. I ended up buying a lot of extras just to get a good price. |
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Fig.2 Begin by removing the plastic cover over the filter/separator (13mm socket). This would also probably be a good time to remove your battery cables to keep your friends from nicknaming you "Sparky" or "Torch". There are some hot solenoid connections close to where you will be wrenching. |
Fig.3 Place a suitable container under the passenger side of your engine below the drain tube to catch fuel. (Note: this pan was not pushed back far enough, had a pretty good mess to clean up...a short hose attached to the end of the drain tube will help.) |
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Fig.4 Rotate the drain valve clockwise to drain your filter/separator. Be sure to check the position of your drain pan at this time... (This would also be a good time to disconnect any electrical plugs that may be in the way.) |
Fig.5 Push the rubber connector to the drain tube off of the lower part of the drain valve. A big fat screwdriver worked good for me. |
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Fig.6 Remove the 4 T20 (Torx) screws with a small T20 socket and ratchet. You might want to place a towel or such below the valve so you don't have to fish a screw out of the valley like I did.. |
Fig.7 Note that the valve assembly is in 2 parts. It's real easy to drop the lever part into the valley. (Don't ask) |
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Fig.8 Carefully pop the old o rings out of the valve body, taking care not scratch up the o ring seat or valve. |
Fig.9 Wipe any existing crud from valve pockets and push in the new o rings. On some models, there is a third o-ring on the top of the stem (pull the stem out from the top to replace), these ARE included in my kits just in case. Wipe any crud off the o ring surfaces on the filter/separator and reverse procedure to re-install. |
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