Rebuilding the Fuel System
- Thread starter RBBailey
- Start date
RDavisinVA
Technical Excellence Contributor
So let me get this straight, in summary.
The gasoline engine side pickup from the sender doesn't go deep enough into the tank for this particular 300TDI routing, assuming the original sender is in place...
AND
The fuel return that goes in from the top is typically above the fuel level in the tank.
To fix it you block off the top of the tank return and replace the gas sender in the side of the tank with a diesel sender.
Is this what you have conveyed in multiple messages?
The gasoline engine side pickup from the sender doesn't go deep enough into the tank for this particular 300TDI routing, assuming the original sender is in place...
AND
The fuel return that goes in from the top is typically above the fuel level in the tank.
To fix it you block off the top of the tank return and replace the gas sender in the side of the tank with a diesel sender.
Is this what you have conveyed in multiple messages?
LOL, yeah. I usually read the messages, get the main idea; then when it comes time to go order the parts, I need to go back and make sure I'm doing it exactly right, and that I have the picture in my head of all the components, and what they do/how they work/how they will fix my problem, and how they fit. It's just my odd way of making sure I know what I'm doing. And with all the wrong/broken parts that were sent to me over the past year, I'm extra careful at what I order.
RDavisinVA
Technical Excellence Contributor
I appreciate the time Napalm00 spent to suggest a solution, but was not 100% sure of my comprehension.
That's why I wrote up the post 22 summary.
Let's see if Napalm00 confirms.
We have a 110 in the shop that originally had a 2.5 petrol.
Owner now has a diesel and his complaint is running out of fuel at 1/2 a tank.
That's why I wrote up the post 22 summary.
Let's see if Napalm00 confirms.
We have a 110 in the shop that originally had a 2.5 petrol.
Owner now has a diesel and his complaint is running out of fuel at 1/2 a tank.
Napalm00
Technical Excellence Contributor
Close.
The gasoline sender/pickup is In the Top....not the side.
Replace the v8 top pickup/pump assembly with the top return elbow part number Ntc2156, it's gasket and probably new mounting screws. Move the return line from the vent to the top return elbow you just installed. Block off unnecessary vent you just removed the line from. Install diesel pickup /sender prc8463 and It's gasket and lock ring in side of tank connect diesel feed for engine to this. PRC8463 has two spades and a ground lug; ground the threaded lug, connect the two spades to the same sender wires from the old v8 top mounted pump/sender. The wiring colors may not be the same and you may need to swap the connections. One spade sends the level, the other in conjunction with the ground is the low fuel dummy light on the dash
This only applies to trucks with the rear mounted 18/19 gallon metal tank
Napalm00
Technical Excellence Contributor
some pics of my setup.
pic one is the tank level sender and the fuel pickup/feed for the engine
pic two the the fuel return on the top of the tank
pic three is the blocked off vent port on the forward right corner of the tank (depending on the revision of the tank you have this may be in a different position)
Pic four is the fuel filler and filler vent tube
pic one is the tank level sender and the fuel pickup/feed for the engine
pic two the the fuel return on the top of the tank
pic three is the blocked off vent port on the forward right corner of the tank (depending on the revision of the tank you have this may be in a different position)
Pic four is the fuel filler and filler vent tube
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RDavisinVA
Technical Excellence Contributor
This clarifies very well.
Napalm00
Technical Excellence Contributor
no prob.
usually the reason the v8 top pickups seem to work for a while is because they do. Then the pump can, mesh filter or connector hose gets jacked up on that assembly. Then the truck has to pull fuel from higher on the assembly making you run out of fuel before the tank is empty. combine that with it just spraying the return diesel from above the waterline you are going to pickup tons of air in the system.
The bummer is that the diesel sender is fragile and has to be bent into the correct position when installing.
After figuring all of this out I now understand why people move to the plastic tanks, they are a much better system, albeit more complex.
and a final shout out...Trevor has all these parts required
usually the reason the v8 top pickups seem to work for a while is because they do. Then the pump can, mesh filter or connector hose gets jacked up on that assembly. Then the truck has to pull fuel from higher on the assembly making you run out of fuel before the tank is empty. combine that with it just spraying the return diesel from above the waterline you are going to pickup tons of air in the system.
The bummer is that the diesel sender is fragile and has to be bent into the correct position when installing.
After figuring all of this out I now understand why people move to the plastic tanks, they are a much better system, albeit more complex.
and a final shout out...Trevor has all these parts required
Napalm00
Technical Excellence Contributor
They are sized by inside diameter mm. Better old school auto parts stores will have them, you will need to measure the hose you have on your truck unfortunately
The EU and USA made ones are definitely better than the cheap Chinese Dorman ones. I'm a cheap ass with some stuff... Well most things but these the quality matters
The EU and USA made ones are definitely better than the cheap Chinese Dorman ones. I'm a cheap ass with some stuff... Well most things but these the quality matters
5/16 id hose
My .02.
Buy yourself a new twist ring and gasket for the side pickup/sender of the tank.
I buy the metal twist rings in bulk, they seldom last very long. The rubber sealing ring works by simply getting sandwiched bteween the tank flange and the sending unit. Re-using age hardened old ones tends to result in a weeping leak.
My .02.
Buy yourself a new twist ring and gasket for the side pickup/sender of the tank.
I buy the metal twist rings in bulk, they seldom last very long. The rubber sealing ring works by simply getting sandwiched bteween the tank flange and the sending unit. Re-using age hardened old ones tends to result in a weeping leak.
Napalm00
Technical Excellence Contributor
Figured I'd throw an update in this thread. My fuel level sender prc8463 has recently started acting up, only reading half tank with the tank full. I removed and adjusted the contacts to no avail... Bummer
I'll be getting a new one in the next week or so and I'll take pics of inside the tank with the top dump elbow installed so you can see how it looks.
I'll be getting a new one in the next week or so and I'll take pics of inside the tank with the top dump elbow installed so you can see how it looks.
Napalm00
Technical Excellence Contributor
here is what the fuel dump elbow looks like when it is installed it is the gold rod in the center of the picture . I was replacing my level sender as it happened to go bad recently .
You can also see the vent pipe hole in the upper left corner of the tank, This is where your fuel is returning to the tank if you are plumbed incorrectly .
You can also see the vent pipe hole in the upper left corner of the tank, This is where your fuel is returning to the tank if you are plumbed incorrectly .
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Roverman2010
Well-known member
Napalm00
Technical Excellence Contributor
No this whole thread is for 200 engines. The OP has a v8 fuel system in the rear of the truck and needed to upgrade
Lift pump banjo bolt is metric but unsure of size, and Yea it is a special bolt that has a restriction built into it.
The lift pump is 1/2 unf that you can use a 1/2x20 straight fitting adapter with a crush washer