6.0L diesel fuel leak under hood
 

2003, <nobr style="font-weight: normal; font-size: 100%; color: darkgreen;" id="itxt_nobr_0_0">Fordhttp://images.intellitxt.com/ast/adTypes/2_bing.gif</nobr> Excursion, 2wd, 6.0L limited - 81,000 miles

Help please.... It seems I have a diesel leak under the hood. It started a few weeks ago where we would smell raw diesel in the cabin. It has gotten worse. i looked under the hood and saw it wet around the metal tubes connecting to the fuel bowl (under the hood fuel filter). i think I saw 4 metal tubes going to the bowl. I took the fuel filter cap off to inspect for a crack...and didn't see a crack in the bowl. I have read on other posts about new o-rings for the 7.3L but haven't found anything for the 6.0L.

When the car is parked, it seems to leak a small puddle of diesel under the truck. Are the metal tubes going to the fuel bowl, where the o-rings are? It looks like there are connectors on them. I assume there are o-rings in the connectors. Do you need any special tools to disconnect the connectors and put new o-rings in them? Any ideas of anything else this could be? Anyone know where to buy the new o-rings for them and is it a job you can do yourself or do you need to take it to the stealership?

I am not any expert on this but isnt there a place underneath where you can drain of the system for water ? If there is no water in the system maybe that valve is leaking ? I know our work truck (03 F550) has one but I dont know the "technical " term.

Yeah thanks...... its leaking up under the hood though. I can see it wet around the fuel bowl under the hood. Thanks for the info though!

There is an 'O' ring kit you can get to fix fuel leaks around the fuel filter. My 6.0 leaked there twice and I have had to fix it myself with the kit from ford. With your truck running and a flashlight you can probably see fuel dripping around the fuel filter somewhere.

The kit for the fuel leak at the fuel pressure regulator on the secondary fuel filter the numbers for a 2003 6.0 is 3C3Z-9T517-AE from Ford, and 1843065C95 from International. The numbers may be the same after 03, but im not sure. If you give the dealer your year, make, model, and the base number 9T517 they should be able to figure it out for you.

Thanks Tim! Excellent info. Do you guys suggest any one online place for Ford parts?

Tim, did you change the o-rings yourself or take it to the shop? Wondering if I need any special tools?

I changed it myself (i'm a mechanic) but if you can do basic maintenance you should be able to do this too. You'll just need basic hand tools: sockets, ratchets, extensions, metric wrenches, torx (star) bits and possibly some allen wrenches. Just remove the driver side (intercooler to intake) pipe and make sure you clean out the boots on that intercooler pipe with brakeclean and a clean rag so the oil residue doesnt cause the pipe to blow off after you reinstall it. Then replace the parts that come in the kit. It took me about 30-45 minutes to do at home myself.

Regulator Kit
 

Part # ends in "AG" now.... 3C3Z-9T517-AG.

This would be a good time for you to do the Ford "blue spring" update. The kit comes with a spring that improves your fuel pressure, and the kit also includes all the seals for resealing the fuel fittings.

www.partsguyed.com

More info in the 6.0 forum if you search for BLUE SPRING.

Edit: that's the same kit that dsmiley gave the part number above^^^

Not special, just specific. You'll need a T27 torx bit, I used one mounted in a 1/4" socket. A precision hook and pick set helps get the old gaskets out. Might as well do a new fuel filter, you'll get a new o-ring for the bowl cover that way.

You do this whole process, either just the gaskets, or add the spring, same amount of dissassembly either way:
Fuel Regulator Upgrade w/ Pictures - Diesel Forum - TheDieselStop.com

If you're interested, it's also the ideal time to add a fuel pressure sending unit, either into the test port, or with a replacement billet cover.

The OP was from 3/2010......I hope he's found a way to do it by now.:D

It got resurrected by DSmiley yesterday.:p

:-banghead:-banghead:-banghead:-banghead

I saw Bill respond and didn't check the dates, so I'll blame it on him. :-roll

I'll take it. I've got broad shoulders. :o

Bill > :-X19 < World

Don't worry about adding new information to an old thread, my "04 started pissing fuel out under the truck yesterday and I'm looking at the thread today for the first time. Thankful for info new and old. The pictures and the fuel pressure sending unit idea are very helpful.
Thanks.