How to Install a Ryco Z980UK Universal Fuel Water Separator

With modern diesel engines making plenty of power and torque while delivering fuel efficiency, it’s easy to see why they’re so popular today. However, one thing to look out for is contaminated fuel – an issue that’s particularly common when off-roading and venturing out to rural areas where the fuel quality is questionable. Contaminated fuel can cause big problems for the sensitive fuel systems in common diesel engines, fouling injectors and leading to expensive repairs.

When it comes to protecting your diesel engine from contaminated fuel, fitting a Ryco Fuel Water Separator is your best bet. The Fuel Water Separator acts as a pre-filter for your vehicle’s existing fuel filter, working to remove water and larger particulates before they can reach the OEM filter and the engine. Ryco makes direct fitment kits to suit a wide range of 4WDs, but if there isn’t one available for your vehicle, Ryco also offers the Z980UK Universal Fuel Water Separator. When it comes to fitment, this work should only be carried out by a qualified mechanic.

To fit the Ryco Z980UK Universal Fuel Water Separator, you will first need to do some planning. Work out the best spot to mount your Fuel Water Separator, which should be somewhere near your fuel filter, in a clear space if possible.

From there, you will need to measure up and work out what fuel hose is required. Measure the hose diameter and lengths required for your application, and remember to always buy a bit more hose than you need to allow for error in measurement. You will also need the correct-sized hose clamps to suit.

Next, you will need to find a mounting bracket that will suit the location you’ve chosen for your Fuel Water Separator. In some cases, you may need to customise or make a bracket from scratch to suit, or direct mount the unit to the vehicle. Lastly, you’ll also need some M8 bolts and nuts to mount to Fuel Water Separator to the bracket, as well as some cable ties to neaten up the install.

Please note, you will need to purchase the fuel hose, hose clamps, and all other mounting hardware separately.

In terms of tools, you’ll need a sharp blade for cutting your hose to size, and general hand tools to install the Fuel Water Separator, such as spanners, pliers measuring equipment, and screwdrivers. Be sure to have your tools on hand prior to the install.

Once you’ve done your planning and gotten all of the other parts that you need, it’s time to install the Ryco Fuel Water Separator. There are multiple ways in which you can install the fuel fittings, so decide what will work best for your application. Included in the Z980UK kit are a pair of Ryco fuel fittings and quick connectors to suit.

The Ryco Z980UK Universal Fuel Water Separator comes with a pair of Ryco fuel fittings and quick connectors to suit your application. 

Once you’ve determined the fitting orientation, blank off the unused fuel ports with the supplied blanking plugs and install the two Ryco hose fittings and quick connectors using the supplied seals. We recommend using a vice and a ring spanner here to ensure that the fittings are tightened up securely.

Tighten your fuel fittings with the mounting plate head in a vice to ensure that they're tightened up securely.

With the mounting plate head assembled, you can then fit the Z980UK Fuel Filter and Fuel Bowl together and mount the assembly to your bracket with two M8 nuts and bolts. From there, mount the bracket in your engine bay.

With the Fuel Water Separator mounted in the engine bay, you’ll now need to plumb up the fuel lines. This is a case of connecting the factory incoming fuel line that was connected to the fuel filter to the inlet port of the Ryco Fuel Water Separator.

You will then need to connect the outlet port of the Fuel Water Separator to the OEM fuel filter. Be sure to use hose clamps at all of the hose connections.

Double-check all connections before moving on to the next step.

Once you’ve double-checked all of the hoses and bolts, you can then prime the fuel system. You will need to find out the priming procedure for your specific vehicle. After the system has been primed, start the vehicle and check for any leaks. Once you’ve confirmed that there are now leaks, road test the vehicle and confirm engine is running normally.

After the fuel system has been primed and checked for leaks, the install is complete.