Compression Ignition Addict
Join Date: Oct 2011
Location: Tehachapi, CA
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First, make sure that it is the Fuel Heater Feed-through that is leaking. There are 3 wires on the driver's side of the fuel bowl. From top to bottom, it will be the fuel restriction sensor (located on the fuel pressure regulator block), below that the fuel heater feed through, and finally below that the Water-in-Fuel sensor.
The fuel restriction sensors love to leak. It is 1/8 NPT threaded and can be replaced with an NPT plug (if you change filters regularly, you don't really need it ... just don't overtighten it and crack the regulator housing!).
The Fuel heater Feedthrough (sometimes called the fuel heater thermostat) has an o-ring seal and is held down by the Water-in-Fuel sensor.
The Water-in-Fuel sensor is also o-ringed, but screws in.
If the fuel heater feedthrough is leaking, it's probably damaged (they can get damaged when trying to pry off the spade connector (don't ask how I know this).
Here's the part numbers:
Fuel Filter Restriction Sensor
Fuel Heater Element
Old Style: (Ford) F5TZ-9J294-A (94-97)
New Style: (Ford) F81Z-9J294-AA, (International) 1831196C92, (Dorman) 904-210
(Ford part requires some mods to fuel bowl, Dorman does not)
Fuel Heater Thermostat (Feedthrough)
You will need to remove the fuel bowl for repairs (except for maybe the restriction sensor). Cheers!
1997 F250 SC 4x4, E4OD, 4.10 LS, Basically Stock, Relocated Block Heater Plug, External Trans Filter, Tru-Cool Max, I/C Mounted but not Plumbed
SOLD - 1994 F350 CC DRW 2WD PSD, 5 Speed, 4.10 LS, SBC Con-O, Baldwin Filter, Tymar HPX Hose, DPPI DP, Bilsteins, $12 AIC, Coolant Filter, Explorer Overhead Console, A-Pillar w/ISSPRO Black Ice, EV Boost, and EV Pyro, Modified Pedestal, Gutted EBPV.