Hi, everyone! My 05 CRD is sucking air and I can't figure out where the problem is. I upgraded the fuel filter head to the second generation model, but that didn't help. I am still bleeding out a lot of air from the filter head on a regular basis. I have checked the obvious places - fuel filter and filter head. Where else could there possibly be sources of air leaks? I could sure use some help identifying possible trouble areas to check. Thanks!

Stephen

I'll assume you did not double up on the inner filter gasket (the one that goes on the threaded shaft that sometimes gets left from and old filter when a new one is installed); that the WIF is on tight; that there is no leak around the bleeder screw or the primer pump. If so double check the clamps on both lines to the fuel filter head. If none of those are it I'd suspect the fuel line quick release fittings. I don't know for sure, haven't worked on them, but I think there are 2 (1 of which requires dropping the tank for access - consider an intank fuel pump if you get this far). Those can be cut out of the system and replaced with clamps and high quality fuel line. By high quality I mean marine grade diesel compatable fuel line (e.g. marine grade that meets SAE J1527 type A1-15 marine (USCG) specs or ISO 7840 Type A-1 such as Shields Series 368 from West Marine) which is like $5 per foot but worth every penny over the cheap stuff most parts stores have. I've had really bad experiences with "lesser" fuel line.

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Sold to LOST member my 05 Ltd, GDE Stg II turbo + TCM tune, SunCoast TC w. Transgo kit, Steiger window regulators, Samcos, Fumoto valve, 2nd gen filter head with Lub. Spec. bleeder, Hayden clutch & 11 blade fan, inverted spare, P-1 battery, BF Goodrich Long Trail TAs, Etecno1 glow plugs, timing belt at 50K miles/8 yrs

I did check in the inner gasket already. I did have a double up, but I tried that before I swapped out the filter head. I will check the hose clamps for tightness. Thanks.

So everything is tight and we are still sucking air. This isn't going to be something easy, is it??

Stephen

every inch of the fuel line from the tank all the way to the filter head, plus every inch of the line from the filter head to the injection pump, that's what else could be leaking. Not to mention any and all of the hose fittings.

No, really.

You are right, it isn't going to be easy. Sorry to be the bearer of bad news that way.

But the good news is that replacing fuel lines isn't all that expensive. I mean, compared, for example, to replacing the cylinder head and head gasket -- and while you are in there, might as well do the timing belt, water pump, tensioners and idlers. Just for example.

Naturist is right. Replacing the fuel line isn't that expensive. Having the peace of mind with the new fuel line is worth it in my opinion. You might want to consider installing a lift pump while you are at it. It can help eliminate your air-in-fuel issues also.

Billy

Before I replace the entire fuel line, is there any way to identify or at least verify that this really needs to be done? Thanks!

Having the same issue and running a similar thread at the moment. I just got my Libby back from a diesel mechanic who pessurized the fuel lines and tested the injectors. He claims there is nothing wrong. So the air having to be blead out of my pump every time I use her continues. Hopefully in a week or two I will find time to install in tank lift pump. Good luck with your leak Brother.

Peace,

Thomas

Just a reminder and comments:
1. the CRD fuel lines, at least as far as the fuel filter, are the same as the gasser's. However, the gasser has a fuel pump in the tank hence the fuel line AND the associated quick disconnect fittings are designed to work under internal pressure. In contrast the CRD only has a fuel level sending unit in the tank with the fuel pump (CP3) located on the front of the engine hence fuel is "pulled" from the tank and the lines are all under something resembling a vacuum. Adding pressure at the tank end might push fuel out of loose hose clamps on the other hand it likely will make leaky quick disconnect fittings seat properly and not leak. The underlying problem is the CRD fuel supply system can "suck" air into the lines from any "opening" in the fuel lines. Before someone comments on stupid design I'll just note this is the identical design used on most all petrol engines well into the 1970s as they most all had cam driven fuel pumps mounted on the engine block. So what to do? Make sure all your hose clamps are tight; make sure the hose clamps are not partially resting on the "ball" at the end of metal fittings; make sure the fuel filter/WIF sensor/bleeder screw/primer pump are all seated properly and not leaking; with the exception of the quick disconnect fittings IIRC the fuel lines between the filter and the tank are solid so replace the quick disconnect fittings as noted above.
2. alternatives are a) add an inline (make sure it's one that is flow thru so if it fails it doesn't stop the flow of fuel) fuel pump (near the tank is best but a number of installs in the engine bay seem to do fine) or b) replace the in tank sending unit with a combo sending unit and pump. Lots of how to posts on both.

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Sold to LOST member my 05 Ltd, GDE Stg II turbo + TCM tune, SunCoast TC w. Transgo kit, Steiger window regulators, Samcos, Fumoto valve, 2nd gen filter head with Lub. Spec. bleeder, Hayden clutch & 11 blade fan, inverted spare, P-1 battery, BF Goodrich Long Trail TAs, Etecno1 glow plugs, timing belt at 50K miles/8 yrs