Fuel leak!

[jsimpson]

Fuel leak! Warrantee doesn't cover it!

Fuel is dripping from beneath the plastic cover that covers the throttle linkage at the front of my engine. Anyone had this problem. Something I can deal with without wasting a day at 5-star? FIVE STAR SAYS THE ONLY FUEL ITEM COVERED UNDER THE DRIVETRAIN WARRANTEE IS THE HIGH PRESSURE PUMP!

 

[nickleinonen]

the cp3 pump is right below that [my TPS is under r/s battery tray i believe though so i haven't seen a 3rd gen with an engine mounted tps in person]



it could be the fuel inlet line leaking a bit from a loose fitting. that can be tightened up, but if that doesn't seal it, you can "revive" your copper sealing washers for the banjo fitting by heating them up with a propane torch on a work bench just to when they turn orange/red, then let them cool and reuse them. once you aneal [sp?] the copper, it will seal again.

 

[jsimpson]

It's dripping from the main line running from the high pressure pump to the fuel rail. The connections are tight. Do the ends use o-rings?

 

[jsimpson]

There are no banjo fittings on the line with the leak. Don't know whether or not it uses o-rings.

the cp3 pump is right below that [my TPS is under r/s battery tray i believe though so i haven't seen a 3rd gen with an engine mounted tps in person]



it could be the fuel inlet line leaking a bit from a loose fitting. that can be tightened up, but if that doesn't seal it, you can "revive" your copper sealing washers for the banjo fitting by heating them up with a propane torch on a work bench just to when they turn orange/red, then let them cool and reuse them. once you aneal [sp?] the copper, it will seal again.

 

[jsimpson]

It's leaking at the fitting that connects the high pressure line to the fuel log. The fitting is tight. Must be an o-ring.

 

[jsimpson]

I fixed it

Five Star told me that the only fuel injection component covered under the drivetrain warrantee is the high pressure pump. So I pulled the high pressure line. It has compression fittings on both ends. The inlet end was really cruddy, the outlet end (leaking end) was pretty clean. I cleaned off both ends and swirled a wad of paper towel in the inlets, and then reinstalled it. No more leak. As cruddy as the fitting were, it makes me wonder how much crud got to the injectors when the engine was first fired up? they didn't put the fuel injection together very clean! It also makes me wonder about the price of injectors now that I know they're not covered under the powertrain warrantee. I may pull off my Banks Six Gun and QuickLoader to avoid over-pressuring the injectors. My 03 has enough power in stock form anyway. Or better yet, leave it on 1 unless I NEED 6.

 

[jsimpson]

Test drove it. No leaks until I switched the Banks box to 6, and did a full throttle acceleration run, the leak started again and drenched my engine compartment. Back to the drawing board.

 

[DPKetchum]

Injectors are COVERED under the Cummin engine warranty!!!!As is the Turbo and other releated parts. Power train is 7/70 . The engine and FUEL system is 7/100!!

 

[nickleinonen]

if you had all the parts on a bench, you could re-lap the mating surfaces of the fittings, but on the truck i wouldn't try that as it would be very hard to get the lapping compound out of the fittings with it all in place. a scratch on the seat can cause it to leak at less than 1,000psi, and with your tuner it is leaking somewhere at 26,000psi, so it is just slightly not seating properly