'89 Ford E350 VAN (7.3 liter Diesel)

machmeter62 · May 18, 2009

I have owned this vehicle for several years now, and noticed fuel leakage recently under the engine after shut-down. I removed the engine inter-cowling and noticed fuel puddling on the both sides of the intake mainfold, and pudding in the glow-plug area too.

I started the engine, which was at operating temperature, and noticed fuel seeping below the fuel injector caps. The prior owner had installed an aux electric fuel boost pump to aid in starting after the vehicle set for a couple of weeks, (he said, "causing a noticable strain on the starter and batteries too.") It was also needed for normal operations also. It has worked great for the last few years, but I am not sure the aux pump has damaged, or caused the seepage around the injectors, (four of them sofar are leaking)! I don't want to operate it till the seepage is fixed.

My question to you "Diesel Guru's;" since the engine still runs smooth with no other problems, is it possible to replace only the O-rings under the fuel return caps, or do I need to replace all the injectors at a cost of $200+ also? The electric aux pump that was installed near the mechanical one, was a Holley for non-racing issues, and researching the Holley pump shows a boost of 12-15 psi...I have no idea what the standard Ford mechanical pump rating is.

Also, the actual mileage of the vehicle is unknown, other than it was used for commercial use. Thanx in advance for your opinions.
LEE

kennyd · May 18, 2009

Just buy a "return line kit" like this and you will be all set. BTDT on my '92 F250HD

machmeter62 · May 18, 2009

Ken,
Thanx for the reply; however there is connected rubber tubes going (to/from) each injector cap now that aren't leaking...wouldn't that be a return line also?

Thanx for the kit info, and I will start there, maybe there is blockage in the existing ones, that I can checkout too?
LEE

kennyd · May 18, 2009

The caps get brittle with age...and if you try to replace just the o-rings then there is a good chance it will still leak. Also, if you just try to replace one cap...chances are that the one next to it will leak. Always best to replace everything at once.

DieselPower · May 19, 2009

Like kennyd said it's best to do them all. I have done many of these over the years and once you start messing with them they all start to leak. And also like he said, replace the caps. They crack and get slightly deformed after years of use. The caps, o-rings and return hose doesn't cost that much and is a fairly easy job to do.

machmeter62 · May 20, 2009

GENTLEMEN,
Thanx for all the replies, I don't mind spending the money now by getting all the new pieces; knowing that I won't have to do it twice, which I have been known to do! One other question....do you think the aux-fuel pump is okay, or should I remove it? It does seem to aid in starting, if the vehicle has sat for a couple of weeks.

One other question....is $200 for a set of injector a fair price? I think they are "O.E." also? Or is there a better up-grade? Thanks again.
LEE

kennyd · May 21, 2009

If you search forums like TDS (DeiselStop) or Oilburners(my favorite) you will find that Holly RED electric fuel pumps are popular on these engines. They mount it in the frame rail and block off the the hole for the mechanical pump with a plate from a Chevy 350 engine IIRC.

$200 is a good price for the injectors, there is not much in the way of upgrades unless you also get into rebuilding the IP (injection pump) to pump more fuel. The IP's do need rebuilding about every 150k or so...but you can find a local shop to help you there.