7.3 psd fuel bowl leak

[stanrich]

I am in the process of updating my 2003 EB-50 Sportsmobile. I had a growing fuel leak under the engine and decided to replace the entire fuel bowl with an aftermarket replacement rather then rebuild the 20 year old unit I have. So far this has been a frustrating repair. Access is a challenge even after removing components to get a fair view and tool access to the four fuel lines running to and from the bowl. Long story, greatly shortened, I replaced my fuel bowl along with included filter and fired the van up. All good for about 15 seconds and then the pressure inside of the bowl forced a high volume leak around the cap. First impression was I had a loose cap, but after way to much tightening I still had a horrific and massive leak from the cap seal. Sleeping on the problem overnight I decided I had a problem with the pressure relief valve on the new fuel bowl. (which I purchase to eliminate issues with rebuilding my own bowl). Again, since I had installed 95% of all the previously removed components I had to start over again with the removal of components to allow access to the bowl. After removing the bowl for the second time I inspected the pressure relief valve and confirmed my suspicions about the valve. It was installed incorrectly by the supplier and l had little or no return fuel from the valve which created a massive pressure build up in the bowl. I am including a few photographs that show how the spring inside of the pressure relief valve is not seated properly in the housing. This condition caused the pressure relief valve to not function at all or at such a high pressure that the bowl seals failed at the cap. Moral of this story, always consider the source of your aftermarket products, and in this specific case if you happen to be replacing or repairing the pressure relief valve on a 7.3 psd spend a few additional moment to inspect the pressure relief spring before installing. The close up image shows the spring with a downward angle. The spring should be straight and centered.

[shenrie]

That little valve was the first repair I had to do to my van. First time I parked our new to us van in the driveway it puked a 4’ round puddle. I asked my diesel guy and his exact words were “I’d be surprised if it wasn’t the drain valve”. At the time the van had 150k miles on it. I bought the valve and replaced it, but I didn’t have to do near as much work as your describing. All I messed with was the actual valve and the intake tube. I didn’t need to remove the entire fuel bowl.

[Twoxentrix]

Had a new HPOP installed & replaced with new one a month later - it was defective. A new FASS Titanium dual filter fuel pump had to be replaced for new one because it just didn't work after it was installed. When I replaced my fridge, the new one wouldn't cool at all so they swapped it out and no issue since.
Unfortunately hindsight is merely a discovery of circumstance. I can understand your frustration.

[Lilnuts2]

There is a reason many 7.3 owners do a fuel bowl delete.