fuel in the valley - Diesel Forum

lawrence · 02-07-2005, 09:40 PM

i have searched but can't find a thread about the fix for fuel leaking into the valley, lots of stuff for the drain o rings, plan to replace them as well, i am sure it is related to my filter restriction light not working, is there a kit to solve all the problems while i am in there? would like to test the filter heater as well

95 E350 psd 300,000 miles

BigPigPSD · 02-10-2005, 10:47 PM

There are many reasons for fuel in the valley.

Fuel in the front part of the valley (towards the front of the van) could be leaking fuel hoses from the pump to cannister (2 short blue hoses) ;or the fuel filter cannister has holes that have pitted thru from the inside (caused usually by sand like seddiment on the inside bottom of cannister); or the fuel drain switch on the side of cannister is leaking; or any of the sensor plugs on the side of the cannister is leaking.

Middle part of the valley could be any of the above; plus the fuel punp. The pump has a weep hole similar to the water pump weep hole that starts to leak when its about to go south.

Fuel in the rear of the valley closest to the turbo could be comming from the banjo bolt. It's that big nut (1 1/4) that connects the fuel pump to the fuel supply lines to the heads. Usually the 2 metal washers just need to be replaced.

First thing to do is to clean out the valley dry. paper towels and chopsticks and simple green works good. Brake cleaner also works well. It's really tight in there so taking out the resonator box, air filter box and air inlet tube really helps. Stuff the parer towels or rags down and work 'em down in the valley with the chopstick or some sort of stick cause theres not that much room in the valley. Next, get as much light into the engine compartment plus a stong mini flash light start up the engine and pinpoint the leak. You can start the engine with the air inlet tube and resonator box off.

It's best to work from the inside of the van. I usually take out the two front seats for more room.

It's also great to search the 94-97 forum and archives. They've helped me out alot. Good luck hunting. Hope this helps.

Anthony

lawrence · 02-27-2005, 10:10 PM

Anthony, just got around to replacing the banjo washers, i could see the fuel dripping out from under the fitting, but the drip is still there

is the weep hole near the fitting? the top of the pump is bone dry, i am hoping somebody can tell me where that little hole is, i can't afford to replace a pump thats not leaking

XRACER · 02-27-2005, 11:34 PM

Banjo bolts generally require copper washers, which are one use only. Once they've been tightened down, they can't be re-used.

You did that right.....right?

lawrence · 02-28-2005, 03:58 AM

they are new washers

BigPigPSD · 03-01-2005, 03:08 AM

The weep hole is on the pump itself. If it's still dripping from the banjo bolt I would try another set of new washers. Just remember that it goes...pump-washer-banjo-washer-bolt...and then torque to spec with a good torque wrench. To keep the washers set inline with the each other I used some di-electric grease to hold them in place on the banjo. If it's still leaking from the banjo bolt for sure then I would replace the bolt and fuel lines to the heads. That's the way I would go. When my pump was leaking I had a good view of a dry valley and could see the fuel start to pond on the base of the pump. I couldn't see it actually coming out of the weep hole 'cause I couldn't see the weep hole from the angles that I had, But I knew that it wasn't coming from the hoses off the pump 'cause the paper towels I had wrapped around the hoses were dry. That's what happened to mine. Hope this helps.

lawrence · 03-01-2005, 11:27 AM

thanks for that info, the top half of my pump is dry the bottom half is grimy, which half has the weep hole?