Fuel Filter Leak
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Fuel Filter Leak
I first noticed the problem, when I started smelling Diesel inside the cab when at a stop light, or something along that nature. It was then that I noticed a small/slow leak on the front side of the secondary fuel filter, on the fuel injection pressure regulator. It was here, at ford-trucks.com, that I read about replacing the thermometer shaped o-ring, which I did, but I still have the leak. I looked at the part drawings, and the only thing I can find is either the fuel injection fuel plug is leaking, and that o-ring needs to be replaced OR!!! At the very bottom of where the pressure regulator cover meets the filter housing (sorry do not know the name of hole), there is a port hole that has a spring and another rubber gasket in it (The hole is at where the bottom of the thermometer shaped o-ring meets the filter housing). By looking at the drawing there are no such parts just two o-rings/gaskets that go in that spot. Do I have the wrong parts? Or is there something else I am over looking? Thanks to everyone's help and input.
Lead Driver
Joined: Sep 2007
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From: Scio, OR
The keyhole shaped o-ring should seal the entire pressure regulator. The internal regulator itself changed somewhere around 04 to 05. The early model had a plastic insert that the brass poppet valve and spring slid into. The later version didn't have the plastic insert, the housing was machined and the poppet valve and spring just slid into the hole.
If you still have a leak after changing the keyhole o-ring, then it's most likely that one of the fuel line connectors is leaking. There are two lines going to the head that each have an o-ring. The fuel return line that connects to the regulator cover has two o-rings, one in the brass adapter that threads into the cover and one where the return line connects to the adapter. The fuel feed line uses a banjo fitting with copper washers.
If you still have a leak after changing the keyhole o-ring, then it's most likely that one of the fuel line connectors is leaking. There are two lines going to the head that each have an o-ring. The fuel return line that connects to the regulator cover has two o-rings, one in the brass adapter that threads into the cover and one where the return line connects to the adapter. The fuel feed line uses a banjo fitting with copper washers.
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dchamberlain,
so the plastic piece, or poppet valve, that goes in the keyhole it has a gasket/o-ring that slides on the back...is this the keyhole o-ring you're talking about? I did install an o-ring that goes into the cover where the keyhole would meet the poppet valve & spring. I am pretty sure this is the area where the leak is coming from, and not any of the three connections. But I'll check again, and repost. Thanks again...really appreciate the feedback
so the plastic piece, or poppet valve, that goes in the keyhole it has a gasket/o-ring that slides on the back...is this the keyhole o-ring you're talking about? I did install an o-ring that goes into the cover where the keyhole would meet the poppet valve & spring. I am pretty sure this is the area where the leak is coming from, and not any of the three connections. But I'll check again, and repost. Thanks again...really appreciate the feedback
Lead Driver
Joined: Sep 2007
Posts: 8,180
Likes: 669
From: Scio, OR
This is what the regulator should look like. The brass poppet valve (#2) has it's own little tiny o-right to prevent fuel from flowing around it, but if fuel did get around it the fuel should still be held under the regulator cover and just flow back through the return line.
The only way for fuel to get past the cover would be through the cover o-ring (#4). If fuel is leaking out of the cover, then it's possible the new o-ring got pinched or otherwise not installed correctly. Otherwise, the fuel has to be coming from one of the 4 fuel lines going to the filter housing.
The only way for fuel to get past the cover would be through the cover o-ring (#4). If fuel is leaking out of the cover, then it's possible the new o-ring got pinched or otherwise not installed correctly. Otherwise, the fuel has to be coming from one of the 4 fuel lines going to the filter housing.
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