Fuel heater repair - Diesel Forum

hunterb2 · 12-20-2008, 03:51 PM

Hi guys,

I'm having a problem with the fuel heater on my truck. It's leaking fuel right out of the connection on the top of the filter. It's a blue wire that goes into a black plastic cap on top of the filter. The fuel is coming right out of the cap. I took the filter header off but can't figure out how to get the heater connection apart. I took the big brass fitting that the filter screws onto off but I cannot get the heater to come apart. There must be an o-ring or something that seals the connection but I can't figure out how to get it apart.

Does anyone know how that thing comes apart? If you have an idea I'd love to hear it.

Thanks

Bruce

LMJD · 12-20-2008, 04:36 PM

Quote:

..can't figure out how to get the heater connection apart.

I had to replace mine a couple years ago. I don't quite know what you mean by heater connection. If you mean the wire terminal connector, it just unplugs with some effort. Mine was hard to pop off and another guy here said the same, so they evidently are on there tight due to age.
If I remember right, after taking the brass fitting off, the heater assembly can be pried out from the filter head. There's either one or two O-rings that can cause your leak or like in my case, the wire terminal had cracked loose in the plastic piece and I had to get a new heater ass'y. I was in a hurry so I took it in the shorts from my local friendly Ford dealer---$120. It came in an IH wrapper and I later phoned an IH truck dealer and gave him the part number---$60, so shop wisely.

rednexx · 12-20-2008, 09:37 PM

I have the exact same problem. Once I got the wire connector off, it sprayed fuel everywhere. At this point, I clamped a large hose over it and a bolt in the other end. It still weeps and I think that is what's causing my hard start/no start problem. I hope someone has a solution also. I have a regular filter body housing without the water in fuel sensor and fuel heater that I was going to put in, but I'd rather fix the leak on the original if I can.

cdnsarguy · 12-20-2008, 09:40 PM

Click on my name and PM me your email addy I will forward that info/pics..... just ask for fuel heater fix.

hunterb2 · 12-21-2008, 12:55 AM

Thanks for the replies everyone.

I figured it out in the end. I was referring to the wire connector on the top of the filter head. I got it off eventually after heating it up with my wife's heat gun. Once I got that off I took the fuel filter header off and removed the large brass fitting that the filter screws onto. Once that's off the heater can be pried out of the header. There are 2 O-rings, one between the heater assembly and the header and one inside the assembly itself. It's a bit tricky to get the inside one out as the wire connector has a small tab bent over to prevent it from being removed. Once that is straightened out it comes out quite easily. I went to Ford to get the O-rings and the parts guy looked at the heater assembly like it came off the space shuttle or something. He had no idea where to get the o-rings. He wanted to sell me the whole heater for the bargain price of $265.00. Good grief. I ended up getting the O-rings at a local heavy truck supply place.

Two new o-rings and it's all good. No more leak. Hopefully that cures my start, then stall after sitting for a while.

Thanks for the replies guys. Much appreciated. Thanks again Pete, you always come through with the right info.

Bruce

M.L.S.C. · 12-21-2008, 02:12 AM

Hey, do you know what size those o-rings are? I got one of my filter heads leaking, I don't get an air intrusion but it is annoying... Also, what size of socket does the brass fitting for the filter take?

rednexx · 12-21-2008, 03:59 PM

Thanks Pete! That's exactly what I was looking for.

M.L.S.C. · 12-21-2008, 04:47 PM

Well mine was leaking like a sieve today, the nearest IHC dealer is like 15 miles away, so I figured I'd attempt a temporary fix - my first idea was Permatex gasket maker in the channel for the o-ring and then the o-ring itself on it and then even more permatex, that's always worked for me, but then I saw I have an injector o-ring so I figured I'd give it a try - it needs to be stretched when put on the fuel heater so it actually becomes thinner, and even then the heater still needs to be forced in the hole (which require some grease to be smeared on there), but in the end it worked out nice - no more leaks, none at all!

bentmettle · 12-21-2008, 11:25 PM

you worked on your truck today in Michigan? Brrrrrr!

I am in Ann Arbor, similar issues with my Van. Leaking o-ring that I was going to replace when I had the assembly apart, but the lady at NAPA was giving me a bit of a strange look when I asked them if they had o-rings.

The darn thing has been very hard to start for the past year or more.

I found a bad return checkvalve, but with the heater o-ring leaking, I can't tell if that was the major problem.

Wish there was someone near here who was a BonaFide will work for beer guru!

cdnsarguy · 12-22-2008, 12:55 AM

Just remove the Orings and go to a hydraulic shop and match the sizes........

M.L.S.C. · 12-22-2008, 04:37 AM

Quote:

Originally Posted by bentmettle

you worked on your truck today in Michigan? Brrrrrr!

Yeps, it was 5F at that time, with -16 windchill, had to run inside and warm up my hands every few minutes. But I kinda had no choice, the cold killed caused the darn thing to shrink too much and it was leaking like a sieve when I fired it up.

Quote:

Originally Posted by bentmettle

I am in Ann Arbor, similar issues with my Van. Leaking o-ring that I was going to replace when I had the assembly apart, but the lady at NAPA was giving me a bit of a strange look when I asked them if they had o-rings.

The darn thing has been very hard to start for the past year or more.

I found a bad return checkvalve, but with the heater o-ring leaking, I can't tell if that was the major problem.

Yeps, a fuel heater that leaks fuel out will also suck air in after shutdown, which results in fuel drain off the filter and leads to the lovely no-start situations you're so familiar with. I pulled the return line off my filter head for just that reason - even with the leaky fuel heater I don't experience any air intrusions, truck fires up right away (well, took her like 3 seconds today, but she's been sitting since Thursday).

Quote:

Originally Posted by bentmettle

Wish there was someone near here who was a BonaFide will work for beer guru!

I'm heading out to Jackson on Tuesday afternoon, I take M14 to I94 so I drive right north of Ann Arbor, I'll be happy to swing by your place and give you a hand for a few hours.

bentmettle · 12-22-2008, 04:57 PM

Quote:

Originally Posted by M.L.S.C.

I'm heading out to Jackson on Tuesday afternoon, I take M14 to I94 so I drive right north of Ann Arbor, I'll be happy to swing by your place and give you a hand for a few hours.

I sent you a PM- I'm going to Iowa to see family tomorrow, but will return, eventually, hopefully to a warmer state.

I'm definitely eager to meet someone locally with some IDI experience. I can fix a lot of things, but my van frustrates me horribly quickly and it's a real grrrrrrr to work on with the dog house most of the time...

M.L.S.C. · 12-22-2008, 11:25 PM

Yah, got the PM, sent a reply

radeon1314 · 12-23-2008, 02:30 PM

living in texas, it rarely gets cold enough for the fuel to gell, and when it does get that cold, i put some stuff in the fuel.

are there any adverse effects to tapping and plugging the heater hole?

thanks, kevin

cdnsarguy · 12-23-2008, 10:47 PM

Tap and plug all ya like if you have no use for the heater....... just do not throw it away..... someone may want to buy it.