Fuel System Supply Line Replacement Help

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Aug 7, 2009 | 10:16 PM

powerstrokefever

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Fuel System Supply Line Replacement Help

Hi everybody!

i've got a diesel leak on the passenger side of the engine. we've been smelling raw diesel for a week or so.

i believe it is the fuel supply line that is leaking. i wiped down the engine compartment fuel filter and all lines connected to it. after a few days, i checked and there was no diesel around/on it at all. i jacked the truck up to get a good look from underneath and can see fuel dripping down the passenger side head and down to the under-carriage. it's bad enough of a leak that i really don't like to drive it because it leaves a 3 foot diameter circle.

i would like some help locating on-line maintenance manuals that describe the procedure of replacing this line. i've been googling for a few days and have only located a 2003 6.0 liter Bible at www dan prxy org.

i need a step by step with pictures...lots of pictures

any advice/pointers/help you can offer will be greatly appreciated.

marvin

Aug 8, 2009 | 05:48 AM

npccpartsman

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From: Stuttgart, Ar

Shortened version---fuel lines go from tank to secondary fuel filter under the hood which is next to the oil filter (smaller similar looking black cap). From the secondary filter they go to the front of each head where they are attached with banjo bolts and copper crush washers. If these are leaking they should simply need tightened up. The back of the heads, on a totally stock truck, have allen head plugs in the ends of the fuel galley. These take a 6mm allen wrench to tighten up. If you have a fuel leak from the passenger side it could only be from these two places. I will try to post you up a link from ITP that describes the installation of their regulated return fuel system that hopefully will let you see what to look for. Changing the passenger side fuel line can be a BEAR to get it out and requires quite a bit of engine disassembly.

http://www.itpdiesel.com/other/FuelS...Kit-Manual.pdf

This will at least give you better pictures of what you're up against.

Aug 8, 2009 | 06:30 AM

Maxium4x4

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From: Ohio

Has the truck been worked on prior to your fuel leak and is the leak at the front or rear of the head? As Partsman described you have 2 crush washers on the banjo bolt that attach the fuel line on the front of the head that should be replaced and tightened.

Aug 9, 2009 | 12:53 AM

powerstrokefever

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npccpartsman-thank you for that link and information. while looking up at the back of the head, i didn't see that allen head plugs. before i ask any more questions, though, i'll look at the manual you linked in. thanks again.

marvin

Aug 9, 2009 | 11:50 PM

powerstrokefever

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the pdf link was excellent...thanks.

what is the value of adding return supply line to the 6.0? is it really worth it?
i really don't know, so....

Marvin

Aug 10, 2009 | 12:05 AM

powerstrokefever

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npccpartsman-

if the allen head plugs are tight, could the leak be from inside the heads? seems reasonable to me, but then is this a common thing to occur?

thanks again for that link. the photos showed me exactly what i needed to check those bolts for leaks.

marvin

Aug 29, 2009 | 01:23 AM

powerstrokefever

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Finally found it!

i was all but ready to give up and get nose plugs!!!

the reason i could never find it was i was always waiting for the engine to cool down before looking. why? cause i burnt the heck out my hands the first time on all those really hot parts!

the other day, it was leaking like a sieve and i was so frustrated, i just popped the hood, threw my jacket over the radiator and stuff at the front, climbed up unto the engine compartment and started touching everything around the fuel filter. Voila! there was a major stream of fuel coming from between the filter cap and the housing. i guess waiting till things cooled off gave time for the fuel to run off and evaporate due to heat, so when i went looking, it was nothing to take note of.

anyway, i cleaned the o-ring and put it back together without overtightening the cap, and it's now been a week without neither leak nor smell.