PDA

View Full Version : fuel leak on cold start


bobiz
11-16-2014, 03:31 AM
Hi guys, i have 2003 sprinter ...since the weather got cold i notices that the fuel started to drip from the intake manifold area toward the firewall its impossible to see where exactly the leak is coming from when i start it in the morning to warm it up after about a minute its starts to drip badly so i go under the van with a flash light and see that the leak runs down the manifold ...what there exactly ? when i stick my hand trough the top of the engine i can feel the wet at the end of the fuel bar or what ever u call it i meant the tube that has all the lines that run from it to the injectors and at the end there's some kind of small plastek house attached to it ...to me looks like the fuel return line and thats what im thinking the leak is form .but to get to it looks like the whole manifold have to be removed.....correct me guys on this one

NelsonSprinter
11-16-2014, 04:22 AM
That part is the fuel rail pressure regulator , can be removed without engine removal with a 1" long 1/4" hex socket or eTorx , and there is the $12 seal kit from the dealer.
http://sprinter-source.com/forum/showthread.php?t=29457&highlight=fuel+pressure+regulator

I would check under the black engine cover that it isn't the fuel return line leaking down onto it, since it may have come lose off an injector or at a connection, because that much fuel out of the regulator could prevent a start from insufficent pressure, but a leak from the fuel return like may not prevent a start. It is also called the fuel rail's pressure solenoid if you do a search

surlyoldbill
11-16-2014, 04:25 AM
If it only leaks while it's cold, and the leak stops once the engine warms up, it MIGHT be the high pressure fuel pump seals. Mine did that last year. Mine dripped right down on to the serpentine belt, your's sounds different. Fuel rail solenoid is on the firewall end, and those have a set of o-rings that are known to go bad, but that causes a drop in rail pressure, not a leak as far as I know. Other people have found split or cracked fuel return lines between the injectors and the fuel filter.

bobiz
11-17-2014, 03:03 AM
about that i took the black cover off its super clean no traces of black death at all...how will i see what needed to be taken off i looked at about taking the manifold off looks like it will be impossible to do that with out engine removal...does anyone have any pictures of that fuel rail ? so i can see what need to be done

312d
11-17-2014, 03:16 AM
normally leaks fuel from this o ring below the plastic connector

http://s28.postimg.org/el7sjv17h/diesel_leak.jpg (http://postimage.org/)
subefotos (http://postimage.org/index.php?lang=spanish)

312d
11-17-2014, 03:20 AM
manifold is easy to take out, you will need a external torx E8 or E10, preferably deep socket, also an 2 or 3" extension in 1/4" or 3/8" drive.

pacman_34
11-17-2014, 03:40 AM
See the thread that NelsonSprinter posted. I can swap out the fuel pressure regulator in under 10 minutes.

Take off the plastic engine cover.

Unplug the regulator connector.

Place a towel over the engine since your going to put your face on the engine and reach with your hands to feel in back of the fuel rail.

The regulator has two bolts. Use a hex like the link says and a small 1/4" ratchet and remove the two bolts. Try not to drop them. U cant see the bolts, just have to feel them.

Replace the seals as they are cheap. I have replaced over 10 of those regulators and have a bunch of cores.

When I put the bolts back I use masking tape to tape the bolt to the hex just so it doesent fall off.

DO NOT TAKE OFF THE INTAKE MANIFOLD! THAT IS A HUGE JOB WITH THE ENGINE STILL IN THE VAN.

Missouri Blue
11-17-2014, 03:55 AM
I'm not a mechanic (other than on my own Sprinter) and I totally agree with Pacman... Do not remove the manifold. I have swapped out my regulator many times trying to run down a problem that ended up being the high pressure fuel pump. Your leak is not coming from the fuel pump since the leak is at the rear of the engine.

The regulator/solenoid takes a e-torx 8. Be careful when you are removing to pull straight back and not up because there is a tip that could be broken off. There is a nylon washer and a green o-ring that come in the kit referenced above.

This said, I agree with others that this much of fuel leak from the solenoid/regulator might be unusual with it still starting.

dg55117
11-17-2014, 05:33 PM
I have 2005 145K- never leaked a drop on anything. Yesterday, started- cold(15 degF) and let idle about 15 min - not on purpose. Noticed small spot on ground and had what seemed clear like diesel but not 100%. it leaked and dripped off front drivers side of oil pan but totally dry above that anywhere I could see /feel. Wiped the pan clean and drove 300 miles freeway ( checked under a few times along way) and it was completely dry. Parked in heated garage and no leaks - totally dry. Ram perfectly but it seemed to get a little less fuel mpg but could be due to cold/biodiesel and Powerservice additive
Does this sound like the stat of HP fuel pump? Can I check anyway for sure?
thanks

surlyoldbill
11-18-2014, 12:06 AM
I have 2005 145K- never leaked a drop on anything. Yesterday, started- cold(15 degF) and let idle about 15 min - not on purpose. Noticed small spot on ground and had what seemed clear like diesel but not 100%. it leaked and dripped off front drivers side of oil pan but totally dry above that anywhere I could see /feel. Wiped the pan clean and drove 300 miles freeway ( checked under a few times along way) and it was completely dry. Parked in heated garage and no leaks - totally dry. Ram perfectly but it seemed to get a little less fuel mpg but could be due to cold/biodiesel and Powerservice additive
Does this sound like the stat of HP fuel pump? Can I check anyway for sure?
thanks

When you start it up in the morning and it's cold outside, IMMEDIATELY run out and look around the HP pump with a flashlight for drips. I used a heat gun on mine for a few mornings until the rebuilt pump showed up, and that worked. Kind of disconcerting to have fuel running down the front of the engine, even if it's only for a few minutes.

312d
11-18-2014, 04:03 AM
just to point out some things, i have not said he should take off the pressure regulator I said the other plastic clear tube, the one enlighten with red and second it is not difficult to take off the upper part of the intake manifold at least for me, the bottom part, well that is a PIA.

bobiz
11-18-2014, 04:48 AM
Thanks for you help guys Im gonna give it a shot will let you know how it goes .....I just remembered one more thing I just talked to one guy this weekend he deals a lot with older sprinters he told me that he buys those O-rings from Home depot or Lowe's in the plumbing isle where all the faucets kits are.he assured that they fit perfectly ..any one done this before...

pfflyer
11-18-2014, 04:57 AM
They may fit but what material are they made of and how long will it last exposed to fuel and oil.

surlyoldbill
11-18-2014, 05:41 AM
Thanks for you help guys Im gonna give it a shot will let you know how it goes .....I just remembered one more thing I just talked to one guy this weekend he deals a lot with older sprinters he told me that he buys those O-rings from Home depot or Lowe's in the plumbing isle where all the faucets kits are.he assured that they fit perfectly ..any one done this before...

I did not check the size when I replaced mine, I have the multi-kit from Harbor Freight with about 20-30 different sizes in it; and another one with SAE sizes. When replacing the o-rings on the clear fuel lines, I found that at least THEY are some odd size not in my kit. The ones on the rail solenoid may be the same way. BUT, if your friend says he can get the size needed in a packet at Home Depot, great! Let us know what the id/od/section size is for future reference.

Denislav
11-18-2014, 01:33 PM
Mine was leacking by the plastik end of the diesel return line
See this temporali fitting , go on Community - Pict. and Albums

Aqua Puttana
11-18-2014, 02:26 PM
just to point out some things, i have not said he should take off the pressure regulator I said the other plastic clear tube, the one enlighten with red and second it is not difficult to take off the upper part of the intake manifold at least for me, the bottom part, well that is a PIA.
The 5 cylinder NAS aka NAFTA OM612 engines I've seen do not look like the engine in your previous picture.

:2cents: vic

Aqua Puttana
11-18-2014, 02:30 PM
I have 2005 145K- never leaked a drop on anything. ...
thanks
The OM647 engine high pressure pumps have some history of the rear fasteners becoming loose and leaking. The pump needs removal to correct, but usually no new parts.

If you trace the leak to the HP pump do an advanced search using high pressure with abittenbinder as member name. That should get the procedure. vic

dg55117
11-18-2014, 06:41 PM
Thanks gentlemen

312d
11-18-2014, 11:21 PM
The 5 cylinder NAS aka NAFTA OM612 engines I've seen do not look like the engine in your previous picture.

:2cents: vic

thanks Vic, then it would be nice that someone put some pictures to figure.

Aqua Puttana
11-18-2014, 11:59 PM
thanks Vic, then it would be nice that someone put some pictures to figure.
ok.

This is what is under the black plastic cover of the OM612 engine. The black fabric covered tubing linking the injectors is part of the the fuel return system.

63951

http://sprinter-source.com/forum/showthread.php?p=43095#post43095

vic

312d
11-19-2014, 07:24 AM
the bracket is in front of what I wanted to see.
Mmm... alloy one piece intake, I see why it is difficult, mine is plastic and splitted in two.
VIC rocks !!!

bobiz
11-20-2014, 04:54 AM
I went to Home depot today for some other work things and stoped at the plumbing isle I called up the guy that i talked to last weekend he told me its O-ring #78 its says that on the box its like 10 O-rings in there $2.23 so i got it haven't put it on yet didnt have to tool the Etorx 8 to remove it and H depot don't carry those sockets ether so ill try auto zone later..also I stuck my hand in there wile the engine was running to me it seems like the leak is coming from the fuel return line ..how does that conector comes off of that line?

312d
11-20-2014, 05:01 AM
can you show us with a picture wich one is it?

surlyoldbill
11-20-2014, 05:36 AM
E socket plus Torx set at Lowe's is about $25. Same at Harbor Freight.

bobiz
11-21-2014, 04:22 AM
312d you mean pic of the area where the leak is?

312d
11-21-2014, 05:47 AM
312d you mean pic of the area where the leak is?

the better you show us, the better we can help.

bobiz
11-30-2014, 03:30 AM
im back had no time to follow up here ....i finally fixed the fuel leak it happened to be not the fuel pressure regulator ..it was actually leaking form the return line, it was a PIta taking it off I ended up braking that locking clip on it , took the old O-ring out put new one on the one i got form Lowe's put it in took piece of wire wrapped it around the fuel rail to the house to make sure that house stays in place since i broke the locking clip..No leak so far ...No will be fixing the next thing will be ordering new EGR valve..just tired driving in lmp mode....thanks again u guys