Engine/Transmission (1998.5 - 2002) injector lines

[GKinney]

Does anyone know for sure how the cross tube/injector lines seal?? I noticed that my #3 injector nut is seeping some fuel. I tried backing it off and re-torquing it, but it is still leaking a little. I was told by the mech. that installed my VP-44 last summer that they are designed to leak outwards instead of in the engine,, is that true?? Or is it leaking into the oil too? Well thanks in advance for any help. gary



p. s. it seems to be leaking from the treads on the line nut where it screws into the head and not where the line goes through the nut.

 

[PC12Driver]

The crossover tubes are sealed against the injector and the fuel line by compression from the 19mm nut (where yours seems to be leaking). A smooth surface on each side is needed to get a good seal. Try backing off the nut and cranking back down on it to get things to re-seat.



There is a channel in the head that does allow any fuel leaks at the injector to safely return to the fuel tank (there's a banjo fitting on the back of the head) and not get into the oil. This is a space created by the o-ring at the top of the injector and the copper washer at its base. There is also an o-ring on the crossover tube (which could also be the problem) to keep any fuel from leaking out back around the 19mm nuts. So, since your leak is showing itself around the fuel line nuts, I'd say your leak is probably where the line meets the crossover tube.



So, give it a retorque. If it continues to leak you may need a new crossover tube and/or o-ring.

 

[Mad Bomber]

IIRC when pulling the the tubes out of a 98. 5 you MUST replace them no reusing them.

 

[Mike B.]

How many times may they be reused on a 99. I getting ready to change injectors again. This will be the third time the injectors have been out and the 5th time the lines have been loosened (two failed vp44 pumps). What do you think, should I spring for new tubes this go around?



Mike

 

[PRyker]

What about a 2002? Do I need new connector tubes when installing new injectors? How much are new connector tubes?



Phil

 

[GKinney]

injector tubes

First off, thanks for all the replies. I think my leak may have slowed down, I was hoping to get it stopped long enough until I get some new injectors and tubes installed, and of course adjust the valves while I am in there too. The only engines that I have heard/read about needing any new tubes, are the early 98. 5 models. I have the engine serial # cut off for ones with the "one time only" tubes. Of course mine falls in the earlier category. Thanks again for all the help. . now to get those injectors and tubes ordered... . humm now I have to decide how big!!!! . Most dealers and some diesel shops charge as high as $40-$45 a piece for the tubes, but piers (http://www.piersdiesel.com/DodgeUSPrice.htm) seem to sell the whole set for $85... humm makes ya wonder doesn't it? Well enough for now. Keep 'em smoking fella's, wouldn't be any fun if we didn't!!!!

 

[csutton7]

guys you can reuse the tubes many times from 98. 5 and above--I can't tell you how many times we changed injectors on the late HVAC's(Nowel Thomas) 98. 5 and how many times he changed them before I came along--plus I've changed my injectors at least 20 times on my 99--only reason to change is if you can't get them to seal--but I'd say this doesn't happen very often---chris

 

[RonA]

I just inspect the o-rings and replace as needed. When I put the lines on I put assembly lube on the threads and tighten a little and then back off, tighten a little more and then back off. do this a few times and they will seat and not leak. If you have a leaker, back it off and re-tighten , don't just keep cranking it down tighter and tighter.

 

[Vaughn MacKenzie]

If you have a leaker, back it off and re-tighten , don't just keep cranking it down tighter and tighter.

Yes for sure. The proper torque spec as I recall is 28ft/lbs. No more, no less.



Vaughn

 

[csutton7]

or gudintite... ... ... ... chris

 

[rono]

I forget to tighten one of the little clamps that hold the injector lines after replacing the injectors. (the ones with the blue rubber cushion things). Anyway, the vibration of the engine caused #3 to crack at the pump, and it was pouring diesel. I went to the local Freightliner dealer, gave him the engine number and he went to the back and go the proper line and several of the blue cushions, metal clamps and bolts. Several of the other lines had to be loosened so I could work the #3 line into place, tightened everything up and no problem since.

Ron

 

[Marco]

On the early 24 Valves the cross tubes couldn't be reused! There was a TSB(?) out for that. I really can't remember where that information came from. I think it was from engine serial # x-y.



What I know for SURE is that Nowel had changed his cross tubes. Fact is that I've changed them too because I had a leak after an injector swap. Nowel told me about the "weak" cross tubes. Since then I've swapped the injectors many times, with the "new & improved" cross tubes no more leaks.



GKinney's truck is an 98. 5... could very well be that his cross tubes are the old ones.



Marco

 

[GKinney]

engine numbers

Yes Marco you are correct, I have the early 24 valve engine. The engine number cut off on the 'soft non reusable tubes" is 56462592 and earlier. My engine number is 56445664 hence I have the early tubes that need to be replaced when ever injectors are replaced. I figure since I have had the VP44 replaced twice, I have bled #3 a couple times myself, the tube is probably weak. I am planning an injector upgrade real soon including new tubes, so hopefully that will cure my problem. Anyone know the best/cheapest place to get a set of 275 RV injectors?? I really don't need/want any more that that for now. Thanks for all the help and replies.

 

[RonA]

I have my old 275 nozzles. But you can probably buy new ones cheaper than you could get someone to swap nozzles for you.

 

[GKinney]

problem solved?

Well just wanted to say that I ordered a set of 275's and new tubes from Piers this afternoon. Should be here on next Tues, hopefully after that all my problems will be solved, except for wanting bigger ones that is. . Thanks again for all the help. TDR is always the one stop answer place for us CTD owners!!!!! Damn glad to be a part of it too. gary

 

[GKinney]

leak fixed

Well I got the new injectors and tubes installed today, no more leaks and a little more low and mid range power. Now I need to get brave and put the EZ back on to see how she runs then. Maybe I will sell the EZ and go for a Comp box instead and leave the wire untapped, that way it will be in the cab and is easier to adjust. I feel the bug biting once again!!!!!!



P. S. I was suprised/tickled at how much better/beefier the engine now sounds at idle with just the +40hp injectors, should have went with 60 I guess.

 

[Mad Bomber]

Maybe I will sell the EZ and go for a Comp box instead and leave the wire untapped, that way it will be in the cab and is easier to adjust. I feel the bug biting once again!!!!!!

FYI the 98 and 99 tend to have weaker injection pumps and tapping it with a comp can cause it to fail. Some are good but do you want to take that chance and blow it up?

 

[GKinney]

new pump

madbomber, no I wouldn't tap the wire, plus the VP44 was replaced last July with a new pump that has all the latest upgrades in it. Probably just stick with the EZ.

 

[paulb]

madbomber, no I wouldn't tap the wire, plus the VP44 was replaced last July with a new pump that has all the latest upgrades in it. Probably just stick with the EZ.

Go with the comp. That way you can spend many a sleepless night, wondering what it would be like to tap the wire, and then wondering if the VP44 will fail!



Paul

 

[GKinney]

no sleep

Exactly paulb, that would be me for sure... I am really wondering if I should put the EZ back on, but I sure miss that punch. Well like they say, if you want to play, you have to pay. . but the Vp's are pricey when it comes to playing. :-laf :-laf