Leak from #2 Injector high pressure line

[CSchoepp]

I noticed I had a fuel leak and when I investigated found it was coming from where the high pressure line is attached to the injector with the bolt. I tightened the bolt a couple of times and slowed the leak down a bit, but it kept leaking. I went to my Dealer Service Manual and the only thing I could find was to bleed the HP line (I haven't done that yet). Air in the line wouldn't cause a leak would it? I couldn't find any detail on the what the injector termination of the HP line looks like; is there a copper washer or anyting under the nut that may need to be replaced.



Thanks

Clint

 

[Philip]

The line with the bolt is the return fuel line. The high pressure is the line going into the top of the injector.



There is a copper washer used on the return line. It is two washer connected with a tab. It slides over the fuel return line on both sides.



Any cummins shop should be able to get you one, or a fuel injection shop.

 

[dpuckett]

Might as well get all 6 and replace them. Requires a 10mm wrench and a careful hand to make sure the banjo bolts dont fall down into the unknown.



Daniel

 

[sdstriper]

There is a rectangular ring seal there that has probably deteriorated. Cummins p/n 3909356, they were under $1 last time I checked.



I put together a list of p/n's for the sealing washers, o-ring seals, rubber grommets and rectangular ring seals for the fuel system if anyone is interested. There are several in various sizes for the injectors, fuel lines, return line etc. I was going to replace them all for cheap insurance but it is low on the priority list these days.

 

[CSchoepp]

HP fuel line

Thanks guys, but I am actually talking about the HP line; there is bolt/fitting on the HP line that secures it to the top of the injector, and that is where it is leaking from. The fuel return manifold is fine.



Clint

 

[dpuckett]

Ok, now it is clearer. Remove the injector nut, and see if there is any gunk on there. They normally dont start leaking for no reason..... Hmmm... ... ... Are your hold down clamps in good shape? You need all of them. Start your nut on the injector, and wiggle the line as you tighten the nut by hand. When it is snugged down, and you can turn it no more, finish it with a 17mm wrench.



Daniel

 

[CSchoepp]

corroded line

Finally had a chance to pull the injector line off the top of the injector and take a look. It looks pretty grotty, so I'm thinking I'm better off to replace the line. Should I think about replacing the injector too? How much do injectors cost? Can I change just one injector, or should I change all the injectors at the same time? The high pressure line is $90 at the local Cummins shop.



I'm a little worried that the other line/injector interfaces are in similar condition, but they haven't started leaking yet. That will teach me to drive the truck so little; it's rusting while it sits!



Clint

 

[PToombs]

I have cleaned the sealing area before. Take some fine emery paper, and gently buff the taper on the line, and the injector. Then use some brakleen or such, and wash it clean. Finish with air. Clean it a couple times. I have done this twice, once on a Kubota, and once on a Cummins, and had good luck. I know there is a chance of grit getting in, but the cleaner seems to blow it out. This might save you $90, good luck!

 

[dpuckett]

I agree with PToombs- take some emery cloth and smooth the end of the injector line down. Try to keep it on the same taper, as that is the only selaing surface. I keep the stuff out of the injectors, but he has probably done more work on them than I have. Then again, most ag equipment doesnt get worked on unless it quits, and considering he works for CaseIH (Cummins engines), he may not have much experience.



Daniel

 

[JLEONARD]

And after you clean the "olive" (as the Brit's call it) and get the truck running... if it still leaks loosen that line and let it leak some fuel to clean off the connection then tighten again. That usually works for me.

Jay

 

[PToombs]

CaseIH (Cummins engines), he may not have much experience.



Daniel

Daniel, I don't work on manure spreaders! I work for the Case CE (construction) side! Darn rodeo clowns!

 

[dpuckett]

And the irony is, he is full of it enough so that he needs to work on them just to spread it around :-laf. Seroiously, though, I didnt think of them being seperated- ag and construction are all intertwined together 'round these parts.



DP

 

[bgilbert]

and to hijack

I'm not sure who's got the better job, Scott or Pete. Scott gets to be around/work on that fleet of B series school buses. Pete gets to be around/work on the same thing, only in equipment, not buses, and also knows how to find all the related parts that can be used on our trucks. . just don't come with that expensive 'C' on the box.

 

[PToombs]

just don't come with that expensive 'C' on the box.

Shhhhh!

:-laf:-laf

 

[CSchoepp]

Fixed!

I've started my summer vacation so I finally got a chance to get this done. Pulled the line completely off the truck today; actually didn't think I would be able to salvage it but no one (incl the Cummins shop) had lines in stock. So I attacked with a Dremel using about 8000 grit polishing compound to work out the pitting. After I finished with the dremel I used 350x emery cloth to rough up the mating surface to help get a good seal. Put it back together, started it, bled the air, and took her for a ride. Looks good so far!



Clint