fuel leak - Page 2 - Diesel Forum

rpm1 · 11-03-2009, 08:57 PM

The fuel bowl is gone completely. So the fuel comes from the pump after any pre and post pump filtration to a tee. Then one line to each head. The return lines will come out of the opposite side of the heads to an aftermarket regulator, which is 2 in and one out. Then back to the tank from there. When I did a regulated return like this, it was amazing how much quieter the injectors got since the fuel is not "deadheaded" like the factory system.

I am redoing everything with bigger lines. I will post some pics when I get it done.

clev · 11-03-2009, 10:12 PM

Well, it's 9:00 PM and I just finished the bowl rebuild. I WILL NEVER, EVER, DO THAT AGAIN!!!! I don't care what the stealership charges for the job, it's going to the garage. I'm retired army and thought I knew how to cuss until I got into this; this job gave a whole new meaning to cussing. I spent almost an hour just trying to put the little hose back on the drain nipple. I put it on before I bolted down the fuel bowl, but couldn't move it back enough to start the bolts. So, I took it off and bolted down the bowl. I finally had to bend the pipe which broke it loose from it's clamps, replaced the hose to finally get it on. Then used zip ties to secure it. Not to mention, I had to drive to north Austin, 60 miles just for the o-ring kits; $70 for 5 o-rings and 4 sleeves. Did I mention that I hit a deer on I-35 with my G/wing and tore it up pretty badly? I managed to keep it up, but it's got major damage. Jeez! What a job/week.

Almost forgot; I broke a sensor. It's the one directly in front of the left bowl bolt. Can someone tell me what that is so I can get it ordered.

Thanks to all for all the help I received here and the instructions I d/loaded from guzzle's site were invaluable.

505live · 11-05-2009, 10:16 PM

Quote:

Originally Posted by clev

Well, it's 9:00 PM and I just finished the bowl rebuild. I WILL NEVER, EVER, DO THAT AGAIN!!!! I don't care what the stealership charges for the job, it's going to the garage. I'm retired army and thought I knew how to cuss until I got into this; this job gave a whole new meaning to cussing. I spent almost an hour just trying to put the little hose back on the drain nipple. I put it on before I bolted down the fuel bowl, but couldn't move it back enough to start the bolts. So, I took it off and bolted down the bowl. I finally had to bend the pipe which broke it loose from it's clamps, replaced the hose to finally get it on. Then used zip ties to secure it. Not to mention, I had to drive to north Austin, 60 miles just for the o-ring kits; $70 for 5 o-rings and 4 sleeves. Did I mention that I hit a deer on I-35 with my G/wing and tore it up pretty badly? I managed to keep it up, but it's got major damage. Jeez! What a job/week.

Almost forgot; I broke a sensor. It's the one directly in front of the left bowl bolt. Can someone tell me what that is so I can get it ordered.

Thanks to all for all the help I received here and the instructions I d/loaded from guzzle's site were invaluable.

Glad to hear you kept the bike up! I was feeling like a lame-a$$ since I just forked over $700 on Monday: my fuel bowel drain valve was leaking, and after fixing that they found a leak in the return line on the right head. Suddenly I feel pretty good about it the whole deal.

It is a drag though, for that kind of scratch I could have deleted the bowel and put in the regulated return I bet.

clev · 11-06-2009, 11:12 AM

Can someone help me with the broken sensor?

rpm1 · 11-06-2009, 07:05 PM

Which one is it? wif sensor or heater?

clev · 11-08-2009, 11:39 AM

Sorry for the late reply, my family has been visiting from VA. RPM, I'm not sure what it is, but it's located directly in front of the left fuel bowl bolt. When you back that bolt out, it backs out directly onto the ????sensor???; at least there is a wire that plugs onto it, and I think it's a sensor. In order to unbolt the bowl, the right bolt must be removed first, and as you back out the left, you must push the bowl to the rear, to get more space to back out the bolt. That's about the best description that I can give. Any ideas?

rpm1 · 11-09-2009, 07:41 PM

Clev-I may have miswrote earlier. There is only one plug on the back of the fuel bowl. It is for both the WIF sensor and the heater. Here are some pics.

clev · 11-09-2009, 07:48 PM

I guess I'm not communicating well; the bolts I'm referring to are on the other side of the bowl from what your picture depicts. They're the 2 bolts that actually bolt and secure the bowl.

rpm1 · 11-09-2009, 08:06 PM

Quote:

Originally Posted by clev

I guess I'm not communicating well; the bolts I'm referring to are on the other side of the bowl from what your picture depicts. They're the 2 bolts that actually bolt and secure the bowl.

Nope, my bad. You wrote clearly, I just wasn't reading it right. How about this pic?

It's the exhaust back pressure sensor. It's not connected in the (bad) pic, but a steel tube goes from the bottom of the sensor to the front of the pass side exhaust manifold.

clev · 11-09-2009, 09:15 PM

That's it; also you picture shows another sensor on the right side. What is that one for? The reason I'm asking is my broken sensor looks like the one on the right, but it's in the location of the left one in the picture. Did locations change from '99 to '03?

MikeZR-1 · 11-10-2009, 09:15 AM

Dam Clev, I'm glad you went through this before I did. I have the same problem, glad to hear your ok after the deer

tried to take you out. what part of VA is your family from, I'm in Wmsbg.

clev · 11-10-2009, 03:18 PM

They're on the SW corner, outside of Bristol.

As I reflect back on the job, maybe it wasn't all that bad; any task is difficult the first time. I don't think it would be so difficult the second time. If you attempt it, take out the alternator, unbolt the wiring harness, unplug all connectors, and move 'everything' possible.

I managed to swerve the bike just enough to catch the deer on the right side of the front wheel, so that it was a glancing blow instead of head on.

rpm1 · 11-10-2009, 08:35 PM

Quote:

Originally Posted by clev

That's it; also you picture shows another sensor on the right side. What is that one for? The reason I'm asking is my broken sensor looks like the one on the right, but it's in the location of the left one in the picture. Did locations change from '99 to '03?

The one on the right is coolant temp sensor.

clev · 11-10-2009, 09:47 PM

Thanks for all your help, rpm.