What else to do/check/replace???

[mpdxtreme]

I have had a slight fuel leak into the valley for a while, well today I finally broke down and started replacing things. I started with the o-rings on the drain valve, the old ones were bad. While I was messing around I noticed that the fuel lines from the fuel bowl were all swollen and cracked. Other than Ford where can I get these lines? Also the heater element in the felu bowl was broken, need to replace that also. In the bottom of the fuel bowl there was a handful of "crud", best way too describe it, I dont know what it was but it was hard and there was a lot of it. I am soaking the bowl to try and get it all out so I can see if I have a hole rusted in the bottom somewhere. Other than the obvious things that I am replacing, are there any other things on the topside of the enging that can/will leak that I should replace while I have the topside torn down. The only thing left is the turbo itself. What about the oil lines to the turbo, is that a common leak? I am asking because I dont want to have to do this again for a long time. This truck has been great but I like to fix stuff once and then forget about it for some years.

The truck is a 96 2wd PSD


Thanks Greg G

[hheynow]

Those two lines from the FPR to each head that are swollen and cracked are your fuel return lines. Many have had theirs degrade. Get J30R9 fuel injection hose from any good auto parts store in 3/8" ID. It's a PITA replacing them and you'll need new fittings. Might as well replace all the hoses down there with J30R9 but some are 5/16" as well.

Ford sells the fuel bowl heater for just over $60. Mine is toast so I tossed it and am not going to replace mine for $60. Many run theirs without it. Unless you live in a very cold climate where the diesel will gel and form wax IMO it's not needed assuming your glow plug system and block heater are working fine.

Common fuel leaks come from the sensors screwed in the fuel bowl especially the fuel restriction sensor. The two -202 o-rings on the drain valve should be upgraded to Viton for a one time fix. The hose clamps should also be checked and replaced with fuel injection hose clamps not the cheapo worm gear style.

If you really think after this tear down you won't be needing to monitor any fuel drips for a long while you're fooling yourself. This new formulated ULSD is killing our fuel pumps due to lack of lubricity. Do yourself a favor and add lubricity whether by using biodiesel or an aftermarket additive.

[Ragdude]

is it necessary to remove a/c comp and bracket to get at line to drivers side bank? it looks tight!

[mpdxtreme]

Got it all apart and it looks like it has been leaking for some time. The wire harness that goes to the water in fuel sensor and the bowl heater are toast, the fuel has turned the insulation on the wires to jelly. I was trying to clean them off and chunks of insulation started peeling off and was a gooey mess. I am going to check with ford tomorrow and wee if I can get that little harness. I got the bowl cleaned and the drain valve rings replaces with the vitron ones. Does anyone sell a kit for the other rings on the bowl? The one for the water sensor and heater, since I have it apart I might as well do all them. I am going by NAPA tomorrow and get some fuel injection hose and new clamps to replace the short hoses that were swollen and cracked. Depending on if I can get the parts I should be up and running in a couple days, just have afternoons to work on this. Thank heavens the Toyota isnt giving me any problems, knock on wood.

I didnt have to remove anything A/C related to do this. Just take your time and you should be OK, this is the first work I have ever done on a diesel, it just looks more intimidating than it really is.


Greg G

[mpdxtreme]

OK got the drain valve o-rings, the small harness to the fuel bowl replaced, the heater, and some other assorted parts replaced. It seemed to be ok for a few days, well now it has another leak, it is not from the hoses, drain, or the hetaer and water in fuel sensor. Does anyone have anymore suggestions where to look, it appears that it MIGHT be coming from somewhere on the fuel pressure regulatro, is there any things on the regulator that commonly needs to be replaced? Thanks for the help.

Greg G

[hheynow]

The sensors that thread into the FPR are prone to leak especially the fuel restriction sensor. When I changed my fuel pump I re-threaded everything on the FPR with Permatex high temp thread sealant. So far dry as a bone.

[mpdxtreme]

You are talking abuot the sensor that has the push on electrical connection on it, towards the top of the FPR. Is it under any pressure when I take it out.

Thanks

Greg G