Recently I've noticed fuel on the side of the bed, under the wheel well, on the leaf springs and hitch, etc. Obviously there's a leak somewhere, but I couldn't pinpoint it. I fueled up yesterday (did not overfuel) and got on the interstate. I happened to look in the side mirror and noticed fuel gushing out of the fuel door, as if someone was spraying a hose. I pulled off and opened the cap and more fuel poured out. I left the cap loose, thinking it might help, but as I continued to drive, more fuel was spraying out.

I can't continue to drive the truck like this. I hope someone out there can offer me some advice. Thank you.

 

Do you have auxillary fuel tank? If not then you may have injector loose in head. If copper gastket is leaking it will allow compression into return line. This compression will pressurize your fuel tank . Your vents might be plugged up with mud which would not allow compression gases to escape from tank. To find out remove return line (smaller diameter line) at the left side engine next to fuel supply line to lift pump. Insert clear plastic line that you can get from any hardware store to the steel line, 5/16 diameter. Run it to bucket and start engine there should be no bubbles coming out from line. If there is try to tighten down injectors first donot overtighten.(89 in. lbs.) torque. Fuel return is rear of block connect at #3 at picture location. To check for compression gases in return line.

 

This is from chyrsler tech support help for your problem.
Case Number 932126210
Vehicle Issue Fuel Tank Is Under Pressure. Fuel Coming Out Of The Filler Neck. Check Injector Seals.;Verify that the fuel tank is not over full and the fuel filler neck and vent hoses are not blocked or damaged. Verify that the fuel tank roll over valve is not blocked.
System or Component Fuel Spit Back,Fuel Leak;Customer Concern (No DTCs);Filler Neck,Fuel Fill Cap,Fuel Tank,Injectors,Vent Tube,Group 18 - Vehicle Performance / Driveability;Yes - Intermittent;Fuel Aerated
Recommendation Remove the fuel injectors, check and clean the fuel injector bores, replace fuel injector washers and O-rings. It is important that the fuel injector hold downs and the high pressure fuel lines be torqued properly.

Modification Date 06/25/03 8:19 AM

 

Thanks for the responses, BigIron. Looks like I've got my work cut out for me. I will pull the cover and see if any injectors are loose. Hopefully that's the case. BTW, no auxillary tank.

 

Good luck, the torque on these injectors is very low so rent or borrow inch lbs torque wrench if you don't have one. Get the one that clicks when the torque is reached, cannot see a pointer at the rear injectors very well.

 

BigIron, I have also been having a hard start issue, when the fuel tank gets down by about 10 gals. If I am parked on an incline (nose down) there is no problem. If parked even slightly uphill, or even level, the engine has to crank quite a bit before starting. Once it's started it seems to run just fine. I'm wondering if this lends itself more to the loose injector issue?

 

need to know what year model your truck is

 

Sounds like fuel is draining back to tank. Could also have leaking fuel line or fuel hose allowing air into fuel system. ALso fuel module in tank could be pulling air into fuel lines. What year is your truck?

 

2001.5. See sig. in original post for mods.

 

Perform the air infiltration test outlined in the first response.

If you have air in the return line fuel, then start by replacing all your flexible fuel lines. Same thing for the pick-up tube in the tank.

With a good quality transfer pump like the FASS or the Air Dog, they will continue to transfer fuel when the fuel lines have microscopic air leaks. They also aerate the fuel in the process. Keep in mind the lines will not be wet, just are porous enough to allow air to infiltrate. So, I suspect this is a simple case of failure to perform the routine fuel line replacement that should be done every couple of years on the Dodges.

If that does not solve the problem, then back out the injection feed tubes from the head and pull the injectors and replace the injector seals.

If that does not do the trick, then pull your heads and look for cracks between the exhaust valve seats and spreading to one or more injector bosses. This generally only happens around 100,000 miles or if one of the 24 valve engines have been worked quite hard.