A while back I had fuel leaking out the heater plug on the fuel head so I traded it out for the Racor setup. I had about 25,000 miles on the racor and thought I should change it before a 1500 mile road trip. While I was doing the change, I noticed the fuel line leaving the filter was getting a little torn up at the head where someone (me) had been a little overzealous when tightening the clamp, so I replaced the line, which was a little hard to get to since the other end is down below the turbo hose. I used the in tank pump that I installed 25k ago to prime and she started right up. I went to do a couple errands and she slips into what feels like limp mode, won't go over 3k rpms and after about 3 miles dies and throws the p0093 large fuel leak code. I don't see any visible fuel leaks. I figure air is the problem and check the filter. It was full to the brim and I pumped the primer which felt firm after a couple pumps. Scratching my head I called AAA and used a free tow back home since it was 105 and I was in the middle of an intersection. Next day I double check all fittings and when I turn the key it starts. I let it run in the drive for about 10 minutes and then I do a 30 mile highway run and have zero problems. I chock it up to an air issue and the next week we start our trip pulling a small 5 x 7 trailer with maybe a 1000 pound load. About 450 miles into our trip it dies and throws the code. I get out, look everything over, pump the primer a few times and I can hear fuel. I look down and there is fuel leaking from the water drain of the clear Racor bowl. The drain has a small crack. It is 112 degrees and my wife is NOT HAPPY, and my 2 year old is NOT HAPPY, my 4 year old thinks it is great and wants the wrecker to come again. I get it to start and drive 20 miles back to the town we just drove through get a motel and use jb weld to seal the bottom of the bowl. The nearest parts store open on a Sunday is 60 miles away. The next day we go to the parts place which is a mom and pop store where they still use catalogs and the owner finds a wix compatible filter in order to ditch the plastic bowl, I screw it on and off we go. In about 20 miles it dies again, same code. I sit for a minute and it starts. We drive 120 miles to our getaway near Taos, NM. Everything seems fine. I figure that maybe it was air again from the change. A few days later we make a 100 mile run to Santa Fe and it dies as we approach town. A day later when we head back it dies twice. Each time I just coast to a stop. Turn off the key, turn it back on and it starts. We get back to Taos, spend the week, and it does fine on small trips. I do notice black smoke that I haven't seen before on start up in the morning and it has a rough lope at idle. I have my folks drive out to follow us home just in case someday it doesn't start. I don't want the kids in the heat with questionable cell coverage in the OK panhandle. We drive 600 miles from 9000 ft to 900 ft elevation stopping for fuel and food once with no problems. Now it seems to drive fine. The idle is smooth and I haven't notice a cloud of smoke on start up.
The only problem is every time I start to slow down, my 4 year old asks if the Jeep just died, and my wife gives me this look. Now she wants something reliable, and after the adventure, I don't blame her.
So... After this novel of a story, anybody got any suggestions? It is hard to fix what appears to have fixed itself, but I need something to tell her and even then, it may not do the trick. This is the only time in 75k it has ever had me on the side of the road, other than a flat tire.
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