Filter Housing dissected

retmil46 · **Posted:** Tue Apr 10, 2007 1:16 pm

crdmike wrote:

The warrantied fuel filter head is leaking at the seam; looks like I got to do the gasket. How's yours doing Mitchell?

Doing good. No leaks from the gasket between the upper and lower sections. I replaced the bleed screw with my homemade adapter and a brass radiator drain cock, no leaks in that department either. Coated the hose connections and banjo fittings on the filter head with liquid electricians tape as well. I've run most of a tank thru it now, I'll go out this afternoon and check for air buildup.

Had one other thought on this. If I remember correctly, there's only one 3/8" diameter hole in the upper and lower ends of the fuel heater section, that allows fuel to flow thru it to the filter, and vice versa air to vent off upwards to the bleed screw. I'm thinking a little work with a dremel tool, put some extra holes in this beast to allow better fuel flow and less chance of air being trapped in the filter and heater section.

When I get a chance, I'll get pics of the present setup on mine, and forward them to anyone who can post them here.

crdmike · **Joined:** Tue May 16, 2006 7:25 pm **Posts:** 138

I've thought about this as well. Case in point, when I really get on it, say like entering highway traffic, once I'm up to speed the fuel system plays catch up with a sputter or two before running normal again. It feels more like lack of fuel than trapped air. I will look into this mod when I do the gasket.

BVCRD · **Posted:** Tue Apr 10, 2007 3:45 pm

retmil46 wrote:

crdmike wrote:

The warrantied fuel filter head is leaking at the seam; looks like I got to do the gasket. How's yours doing Mitchell?

Doing good. No leaks from the gasket between the upper and lower sections. I replaced the bleed screw with my homemade adapter and a brass radiator drain cock, no leaks in that department either. Coated the hose connections and banjo fittings on the filter head with liquid electricians tape as well. I've run most of a tank thru it now, I'll go out this afternoon and check for air buildup.

Had one other thought on this. If I remember correctly, there's only one 3/8" diameter hole in the upper and lower ends of the fuel heater section, that allows fuel to flow thru it to the filter, and vice versa air to vent off upwards to the bleed screw. I'm thinking a little work with a dremel tool, put some extra holes in this beast to allow better fuel flow and less chance of air being trapped in the filter and heater section.

When I get a chance, I'll get pics of the present setup on mine, and forward them to anyone who can post them here.

Is the fuel heater needed above a certain outside air temp? Probably wouldn't matter except say on a long trip in the summer where you wouldn't want to bleed the system every other fillup, could you just keep it unplugged for the trip or the summer driving season?

Ranger1 · **Joined:** Mon Oct 17, 2005 7:40 pm **Posts:** 1137

It seems to be the season for fuel filter issues. Yesterday, I noticed an odor of burning plastic while driving to lunch. I popped the hood and saw fuel running out of the fuel heater plug (the one on the right as you face the fuel filter) and the plug was burning diesel smoke! The plug end was black, and part of the socket had melted.

I pulled the filter head apart today and used a new oil gasket per Mitch's idea, which fits perfectly. The fuel heater pins measured 3.5 ohms. Put it all back together, no leaks around the filter head ( none before either) and started it up. I left the heater plug out while it was running to see if it leaked - it did not leak while it was running.

I shut if off and watched the socket - it started leaking. I pumped the primer handle one time. The heater socket drained diesel out! As I let off of the primer pump, it sucked it back in - you can hear the hissing sound of an air leak on that fuel socket. Putting your finger over the heater socket stops the hissing noise.

Bottom line - mine doesn't leak diesel while its running under a vacuum, but when you shut it off, it leaks fuel and somehow ends up burning the connector socket. There was a pretty good plume of evaporating diesel smoke coming off the connector. This also means its an air leak into the diesel line while its running.

This leak is entirely from the heater socket and not from the joint like Mitch's and Crdmikes. Looks like there are 2 possibilities for leaks.

New fuel head unit on order.

crdmike · **Joined:** Tue May 16, 2006 7:25 pm **Posts:** 138

Ranger1 wrote:

It seems to be the season for fuel filter issues. Yesterday, I noticed an odor of burning plastic while driving to lunch. I popped the hood and saw fuel running out of the fuel heater plug (the one on the right as you face the fuel filter) and the plug was burning diesel smoke! The plug end was black, and part of the socket had melted.

I pulled the filter head apart today and used a new oil gasket per Mitch's idea, which fits perfectly. The fuel heater pins measured 3.5 ohms. Put it all back together, no leaks around the filter head ( none before either) and started it up. I left the heater plug out while it was running to see if it leaked - it did not leak while it was running.

I shut if off and watched the socket - it started leaking. I pumped the primer handle one time. The heater socket drained diesel out! As I let off of the primer pump, it sucked it back in - you can hear the hissing sound of an air leak on that fuel socket. Putting your finger over the heater socket stops the hissing noise.

Bottom line - mine doesn't leak diesel while its running under a vacuum, but when you shut it off, it leaks fuel and somehow ends up burning the connector socket. There was a pretty good plume of evaporating diesel smoke coming off the connector. This also means its an air leak into the diesel line while its running.

This leak is entirely from the heater socket and not from the joint like Mitch's and Crdmikes. Looks like there are 2 possibilities for leaks.

New fuel head unit on order.

My leak started out similar to yours but since the replacement I've had the slight leak, more like a seep, around the filter head which sucks air, a very bad thing for a high pressure fuel pump lubricated by fuel. Definitely get that head replaced though Ranger1. Just show them the leak and expect a 10 day wait for parts.

Ranger1 · **Joined:** Mon Oct 17, 2005 7:40 pm **Posts:** 1137

retmil46's idea of using an oil filter seal works perfectly. Something else I tried works also if you're having gasket leaks at the seam - a gasket from your old fuel filter. It fits very well. Too bad mine wasn't leaking at the seam instead instead of the heater electrical socket. With the oil filter gasket, there is more gasket to seal when you put it back together. If we could find a source for the plastic heater element, we could just replace it instead of the entire fuel filter head assembly.

Filter Housing dissected

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