Question about Ford F-250

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My 1986 F250 (4X4, automatic, turbo) has begun to leak diesel from various points surrounding the fuel injectors and associated fuel return lines. I had a visual inspection of the truck and the mechanic told me to replace the return lines (kit:$140.00 labor:$350.00). I just wanted to know if something else might going on that would cause the whole fuel system to start leaking at the same time. I am hoping to adress the root of the problem, not just start replacing parts and work backwards.

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  • corymbrush Jul 19, 2010

    Thank you. This solution makes sense. Why couldn't my mechanic have had that insight?

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  • Ford Master
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No the mechanic is right, this problem is caused by the new (in use about 12 years) clean burning diesel fuel mandated by the Feds, it eats up all the injector seals, the new seals are Viton synthetic rubber and are not affected, ford was doing this repair for free for years as it is a fire hazard, we did hundreds at my Ford dealer, I really suggest u have the Ford dealer repair this, there are other parts that may need to be replaced as well, the injector pump seals fail also.

Posted on Jul 19, 2010

  • yadayada
    yadayada Jul 19, 2010

    I know this info because I am a 35 year veteran Ford dealer service tech (retired now)

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My 1992 nissan terrano blows to much black smoke .how to fix this .some say i have unbirt fuel?


if diesel and turbo , check turbo operation of for holes in the intercooler
if turbo or naturally aspirated check/ replace injector tips as black smoke indicators squirting and not atomizing
if petrol check for excessive fuel pressure, faulty injectors , leaking injector seal
regardless of petrol or diesel --black smoke indicates incorrect air / fuel ratio ( too much fuel) so injectors, intercooler, bad turbo or blocked air cleaner are all candidates for the fault

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Astra randomly cuts out at lights and engine May be sluggish,randomly code is P0093,FUEL RAIL SENSOR?


This diagnostic trouble code (DTC) is a generic powertrain code. It is considered generic because it applies to all makes and models of vehicles (1996-newer), although specific repair steps may be slightly different depending on the model.
When the computer sets this code it senses a large fuel leak in the high pressure section of the engine. The ECM in a diesel always monitors and controls the fuel pressure from the fuel injector pump to the injectors as long as the engine is running.
To set a code P0093 the ECM must sense a sudden large drop in fuel pressure within the system. This drop in fuel pressure can be internal, external or caused by a faulty sensor signal to the ECM.
When this happens, the ECM sets the code, goes into fail-safe mode which will suspend the fuel injector pump operation and allow one minute to pull over before it shuts the engine down. It will remain in fail-safe mode until the key is off.
The engine may run again but investigate the problem first. This problem will not correct itself or go away. The engine could shut down at any time or speed.
Unlike gasoline engines with fuel injection pressures of 30 to 50 PSI, diesel engine fuel pressure runs up in the Megapascal range, from 4,500 to 30,000 PSI. It takes very high fuel pressure to force fuel into the high compression cylinder of a diesel.
As you progress in diagnosing the problem be always mindful of the fuel pressure when the engine is running. It is ridiculously high! You have a code P0093 stating there is a large fuel leak in the system. Use caution when sticking your nose under the hood of a running engine with this code, or wrenching on the fuel system.
Symptoms Symptoms of a P0093 diagnostic trouble code may include:
  • Code set and malfunction indicator lamp illumination (check engine light)
  • Engine will enter fail-safe mode and shut down within one minute
  • Possible large loss of power above idle
Causes Potential causes for this DTC include:
  • Fuel injector failure
  • Fuel line common rail leak
  • Fuel pressure sensor malfunction
  • Fuel pump or lift pump failure
  • Fuel heater constantly on
  • Fuel temperature sensor failure
  • Leaks at any point in the high pressure circuit
  • Electrical connector corrosion or seating problems
  • Fuel pressure regulator malfunction
  • Fuel filter plugged dropping the fuel line volume
  • Injector pump leak
  • Fuel control actuator failure
  • Cascade overflow valve malfunction
  • Short in the electrical harness at the injectors or to the ECM
  • Fuel pressure limiting valve
  • ECM failure
Diagnostic Steps & Possible Solutions
  • Start with the engine off and doing a walkaround inspection for obvious fuel leaks between the fuel tank and the engine.
  • Lift the hood and check the oil and level. If the oil level has risen, smell the oil. If it is heavily contaminated by fuel, an injector most likely failed in the open position. Do not start the engine again until the oil and filter is changed.
  • Look under the hood for leaks. Start at the injector pump and follow the fuel lines to the fuel injector rail. Look at the injectors for signs of leaks.
  • Pull the electrical connector off the fuel pressure sensor and look for fuel in the connector. A failed sensor will allow fuel up through the sensor into the connector.
  • Check when you last changed the fuel filter. A plugged fuel filter will drop the volume enough to set the code.
  • Check all electrical connectors on the sensors and wiring harness to the injectors for missing insulation, corrosion or loose connections. If no obvious leaks have been found, go online and look up the TSBs (technical service bulletins) for your year and make vehicle. Diesels have no lack of problems as the TSBs will indicate.
Look for the code and associated repair procedures and probable causes. Chevy and Dodge reads like a book. The TSBs will include recalls on various items as well.
Look at your warranty. Most diesel engines have long warranty periods for various items. Many cover injectors for 7 years or better and 200,000 miles.
The dealer is the next step if no deficiencies are found. Checking the fuel pressure and the operation of the ECM takes special tools for a diagnosis.
Tip: Diesels outlast a normal gasoline powered engine when properly serviced. But they demand service at specific intervals to operate properly. There is no free lunch with these. Do not use any seals or gaskets that are not OEM. The pressures and temperatures call for the use of certain materials resistant to these temperatures and pressures.

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1 Answer

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take it to an accredited diesel specialist shop as pressure there exceeds 25,000 psi unless it is a injector return line where it will be low pressure
could be a cracked line
at any point it is not a job for DIY

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1 Answer

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if it is a common rail diesel then the pressure in the return line would burst it as the line is not capable of 25.000 psi
so the return line will have low pressure if it is blocked some where

have the injectors tested as there may be a tip seat problem that prevents it from starting and the compression pressure is making the pressure in the return line past the needle

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2 Answers

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Are you certain that you put diesel fuel in the car? Had to ask that question. How long did the car sit before you refueled? If it sat for a while and if the temperatures and humidity were enough to produce a build up of water vapor, that might keep the injectors from sending "dry" fuel to the cylinders.

Just running out of fuel won't harm the glow plugs (hence poor starting) and won't require need for a new battery unless the current battery was failing even before draining the tank.

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1. Blocked air intake
2.Incorrectly adjusted timing
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4.Obstruction in fuel filter
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6.Insufficient fuel supply from tank to injector pump
7.Obstruction in fuel tank filter
8. Pinched or restricted fuel return line
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10.External compression leaks ( glow plugs or injectors)
11. Obstruction in injector nozzles
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Just with what you have said I would say its time to drain and or replace your fuel filters (there are usually 2: a primary and a secondary)

There could be a clog in the fuel filter, kinked lines somewhere (so check the lines make sure they are working) you could have an internal fuel filter leak (so it just returns to the fuel tank) or a fuel leak elsewhere.

By the way, be careful with diesel fuel lines, depending on the fuel pump (mechanical or electric) pressures range from 3,000-25,000 PSI maybe even higher!

Check the lines, and drain or replace fuel filters and let me know what you got.

Hope this helps you out.

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