Need some help with my Powerstroke ASAP

[OldRedFord]

Noticed a puddle of fuel in the valley of my 7.3 engine under the mechanical fuel pump. Im of the understanding I have to remove the fuel filter housing to get the fuel pump out.

What is the brass block with the lines on the drivers side of the fuel filter housing?

Do I have to unhook any hard lines? Can I get the O-rings down at Advance or Autozone? I have to have my truck back up and running today or tomorrow.

I am thinking the leak is either from the lift pump or the rubber hoses on top of the engine.

How do I relive the fuel system pressure?

Its a 1997 7.3

[forrestbump]

First, I'm NOT that familiar with 7.3 PSD's, but with a gas 4.0 '99 ranger I once owned, I simply pressed the fuel pump inertia reset button to the "off" position than turned the motor over with the ignition until I was sure the fuel rails were empty and NOT pressurized with fuel.

I was than able to disconnect the fuel lines and such to perform my repairs.

Will this work on a 7.3 PSD? Don't know for sure. I hope others with more knowledge will chime in for you.

[71fordkid]

There are two places common for leaks on those. One is the fuel/water drain valve on the fuel filter housing, and the other is the mechanical fuel pump/lines. make sure you know which one is leaking before you go diving in!

The mechanical fuel pump only supplies 3-10 psi, so bleeding the pressure shouldn't be a problem. However, if the tappet on the bottom of the pump falls out when/if you remove it, the pump needs to be replaced. To get the fuel pump out, you'll need to take the compressor outlet y pipe on the turbo off.

Im assuming the "brass block" your talking about is the fuel control manifold, aka fuel pressure regulator.

the fuel water seperator is the more common of the two, and its fairly easy. you can do it while its still on the engine, or you can take the fuel filter housing off. the valve is a ball-type valve, and its sealed by two thick o rings. I would reccomend getting a kit and replacing the entire fuel/water drain valve, as opposed to just replacing the o rings.

You may be able to get the o rings/kits you need at a parts store, but I havent had very much luck with anyplace but napa or the like with diesel parts.

[OldRedFord]

Ive got it narrowd down to one of the hoses between the pump and filter housing.

Also will plain old fuel hose work?

[71fordkid]

as long as its fuel rated hose for a fuel injection system (i'd use EFI hose as opposed to carb hose, just because its rated for higher pressure), regular fuel hose and screw type hose clamps will work. Good luck!

[OldRedFord]

Its still leaking. I checked all the clamped connections between the fuel bowl and the fuel pump and they are all dry. I used clamps like these here http://www.summitracing.com/parts/IDC-52F15/

After driving for ten miles there was a small puddle still under the fuel pump in the valley. Maybe enough to fill a shot glass.

Also now the warning light for the charging system is on. The day I started all this work it was flickering on and off. Then stayed off. Now its on again. I used a volt meter and checked between the post on the back of the alternator and a negative battery terminal and got 14 volts with the engine running.

Maybe I jarred something loose?

Im starting to get really frustrated working on this. Stuff is really crammed in there.

[71fordkid]

Jarring something loose is always a possibility. as for the fuel leak, try looking in that area with the truck running, if you can see down there.

I know what you mean about stuff being really crammed in there, I specialize in 6.0L and 6.4L diesel repair. its a pain.

[Ranchero50]

Im starting to get really frustrated working on this. Stuff is really crammed in there.

You were warned... I would suggest cleaning everything and taking it around the block or just letting it idle for fifteen minutes. That's how we find leaks at work. Feel everything, assume nothing.

Jamie

[OldRedFord]

Yea I was warned. Otherwise the truck is great. After the wait to start light goes out, just bump the starter and it fires right up.

[OldRedFord]

Are the steel washers on the banjo bolt on the back of the fuel pump a one time use deal? Or do they not need to be replaced when you remove the banjo bolt?

[Ranchero50]

It depends, they are usually copper but I'm not sure about your application. If you dinged them, replace them, if they leak, replace them. Don't overtighten the banjo bolt, it'll break easily. You should take it apart and make sure the machined faces are ok on all the parts. usually the washer drops down on the bolt and get's tweaked.

Jamie

[OldRedFord]

The charging problem...wire on top of the alternator I had wiggled loose when I was laying on it.

Got the new fuel pump installed and put close to ten miles on the truck. No fuel in the valley thus far.
Also replaced the banjo bolt washers while I was in there. I think it was $5 well spent.

I will add tho, if I had thought about it and had the money I would have done a electric fuel pump conversion and a better fuel filtration system. Ill save that for the next time it decides to leak fuel on top of the motor.

I came real close to removing the turbo to install the banjo bolt into the back of the new fuel pump.

[67fordman1]

Had a leak similar to yours a couple weeks ago, replaced fuel pump, new fuel lines with new clamps, still had a very slight leak after about 5 miles. Inspected closely and located the real culprit, the water/ fuel seperator switch.

[OldRedFord]

So last week I worked on a deck. Went over Saturday to collect the rest of the money I was owed. On the way over I stopped and put fuel in the rear tank of my truck. I should add that every time I try to fill that tank I cant put the nozzle into the fuel filler neck all the way or the pump kicks off. Almost have to have the end of the nozzle out of the tube to get the fuel to go in without tripping the pump. I dont have this issue with the front tank.

This fill up I decided to fill the rear tank till I could see fuel in the filler neck. (What I was told to do to get a accurate check on my fuel consumption)

On my way over to the house I made a fast stop at a read light. Didnt think much of the diesel smell I suddenly noticed at the time because I was right next to a gas station that was getting fuel.

When I got to my destination the diesel smell was stronger so I got out to have a look. Walked to the back of the truck to find fuel running out of the back tank from the top and onto the ground.

Pulled my truck up my buddies driveway to get the tank going down hill to slow the leak and then I now had fuel running out from under the hood.

$105 later I had the truck towed 24 miles home.

Im still not sure why I had fuel running out of the tank like that. But the leak under the hood this time was one of the high pressure fuel lines. I had redone all the low pressure lines when I did the pump.

Two lines cost me a total of $80 and they look a lot like hydraulic lines. They just dont look like $80 worth of hose and fittings.

No leaks so far.

Some of the diesel fuel that was in the valley of the engine has turned into this ashy looking stuff...what would be a good cleaner? Couldn't really get paper towels into everything.