Major fuel leak from rear injector line!

[Lou M.]

Got home last night and smelled fuel. Got out of truck only to see a massive amount of fuel pouring underneath my truck! I really couldn't tell where it was coming from because it was everywhere..... After cleaning up the huge mess I did a search and found another guy with an 03 that had the same thing happen. He found his leak at the rear(6th) injector line. I looked at mine and I think that is where mine is too. Everything is tight and no loose fittings. The dealership took his apart and put it back together and fixed the leak. Mine is going to the dealer tomorrow. I'll post again with results. I wonder if this is going to be a weak link, hopefully not. I only have 4,000 miles on the motor. Anyone else ever had this happen? Oh, I forgot to mention this happened after playing with a 3/4 ton Chevy gasser on the highway at speed. He lost, but so did I, I guess.



Lou

 

[kaptn]

I put oversized lines on and noticed that one wasnt quite right before installation ( not a perfect cone shape ). It blew racing a gasser one night. I tried everything to make it work sanding and polishing. Eventually I had it sent out and a new end was put on.

I wouldnt settle for anything else from the dealer. A new one that is as you dont want to get stranded somewhere if it lets go again.

 

[KLockliear]

First I've heard Lou... keep me informed.

 

[Peter Campbell]

Be real carefull when looking for the leak. A diesel spray under that pressure will inject under the skin. The only treatment is to remove the contaminated flesh. Otherwise it will become gangerene? affected. Would really suck to get hit in the face. It has happened from what I heard. Fatality.

 

[jwilliams3]

Your pressure box is exposing a weakness in your fuel system.



The reason this happened is while you were racing you loaded your engine and were @ WOT.

Raising your fuel manifold pressure (common rail) to extreme levels.



I did see another example of a #6 or return fuel line failure on an 03 at Scheids.

This truck was on the dyno and only starting leaking fuel during the dyno run. (max load, WOT).



The leak did not stop after the dyno run.



Make sure to keep the fuel system closed (do not open, work on, modify) while your engine is running.

The common rail fuel system has caused 2 fatalities (none from a Cummins).



--Justin

 

[Lou M.]

Ok, I've got good news and more good news. I had my truck towed to dealer today. As soon as my truck was dropped off from the tow a mechanic walked up to me and asked what was wrong with my truck. Kinda freaked me out! That is always good news! I responded by telling him I had a leak and showed him where I thought it was coming from and was correct. He got a wrench and checked the #6 injector line and sure enough it was loose. The other good news. He tightened it and then checked all the others and eveything was tight. He said he has seen some 03's coming in for same problem. The factory sometimes isn't properly tightening the #6 line. He also said it is more common for that line to get loose due to the fact that it is closest to transmission thus more vibration. I've never had such a lucky and quick(10 minutes) service experience. I wish a mechanic would come out everytime and fix stuff on the spot like today! Ya, right. Check your #6 line from time to time.



Lou

 

[KLockliear]

Good to hear it was a quick and painless fix. I bet you just added a 19mm open end wrench to your truck kit.

 

[Lou M.]

Yes I did.

 

[proudrammer]

I had the same thing happen to the #2 fuel line. Took it to a dealer and they took the line off... everything looked fine... . put it back on and it has not been a problem since. That was 6000km ago. Freaked me out at the time. . all is well now... got to love this truck!!!



Proudrammer