Crack in injector line #5

[LHirshman]

Hello everyone, it has been a while since I had a problem with my '05 2500 (a good thing). Well last Sunday about 10 miles north of Scranton on I81 I am smelling diesel fuel. I pull off of the nearest exit, look under the hood and fuel (lots of fuel) is spraying from a crack in the weld by injector #5.

So now the questions. Should I replace all the injector lines? I remember reading long ago on this forum that the #5 and #6 were pron to this failure. Should I replace the line from the CP3 to the common rail as well?

Replacing the line(s) seems straight forward. Are there any things I should be mindful of? Any tricks of the trade I should be aware of? I am planning to get whatever tools required from Geno's as well as the fuel lines.

Thanks in advance for any advise.

 

[Ozymandias]

Just #5, that's fine in my opinion.

Change is easy - but - keep it clean, clean, clean!
And flush the new line with brake cleaner before installing it.

 

[LHirshman]

Is this failure common? I am running a tuner which, I assume, increases rail pressure somewhat.

 

[AEdelheit]

The isolator on #5 is updated as that was the source of the issue, cant remember if #6 is updated too but no need to replace 1-4 unless you want too.

 

[BigPapa]

The most common line failure is #4, commonly mistaken as #5 because #6 comes off the end of the rail.

 

[AEdelheit]

The most common line failure is #4, commonly mistaken as #5 because #6 comes off the end of the rail.

Doh, I forgot that 6 came off the back, thanks for pointing that out!

 

[Ozymandias]

Is this failure common? I am running a tuner which, I assume, increases rail pressure somewhat.

Increased rail pressure opens a can of worms.
Use an other tuner.

 

[cerberusiam]

I have replaced 3,4, and 6 injector lines for various reasons, #1 has to be installed just so or it leaks. If you can afford it replace them all, it is one of the cheaper things to replace on these engines.

 

[LHirshman]

When you say, "#1 has to be installed just so or it leaks." Any tips on getting it "Just So"?
Do the fitting line up perfectly with the Rail and Injector tube?

 

[cerberusiam]

Yeah, you have to get aligned just right before tightening the nut. It has a small nick in the sealing surfaces form NOT being aligned correctly at one time. I cleaned it up as much as possible with fine Emory cloth to get it to seal if it is perfectly positioned. Not the rail side that is the issue, it is the tube side that has the most problems.

 

[LHirshman]

Would you advise the supply tube from the CP3 as well? Did you get your parts from Geno's Garage, are the OEM?

 

[cerberusiam]

Replace supply tube if it looks like it has corrosion or any problems, same as all the rail lines. Easier for me to just got to Cummins and get the lines with discount thru my sons work. Geno's lines should be fine as I think they are OE parts.

 

[LHirshman]

Well Thanks for all the advise.
Hopefully it will be another few years till I need assistance again.

 

[BigPapa]

So, was it actually #5 or was it #4? I’ve said it many times, if I had a 5.9 CR I’d carry a #4 and a wrench in the glove box.

 

[LHirshman]

Looking at the injector, it is #5.
I just ordered the #5 line and the tool for holding the injector tube nut from Genos Garage.
Once the truck is repaired, I can bring it home and get to the other lines.

 

[nibroc]

I've got #4 in the glove box

 

[LHirshman]

I hope you have it clean inside and stored in a clean plastic bag. Those injectors don't like dirt.

 

[nibroc]

"it" is just the inj. line---not the injector

 

[Ozymandias]

"it" is just the inj. line---not the injector

And where goes the fuel that flows through this line?

 

[BigPapa]

I hope you have it clean inside and stored in a clean plastic bag. Those injectors don't like dirt.

And where goes the fuel that flows through this line?