Engine/Transmission (1998.5 - 2002) Possible Crossover Tube O-ring Leaking

[firefighter_2000]

About 3 weeks ago I had to fix the fuel heater on the fuel filter housing (replace the o-ring). After buttoning everything up had trouble getting the truck to fire off. Finally cracked the 1 & 3 injectors and cranked for a bit and finally got it to start. Truck ran fine for the next two weeks till a couple of days ago. Went out to start the truck, and no start. Good LP pressure. Took till the third ten second crank for the truck to fire up and it ran great with no problems. Stopped the truck and it would start back up several times with no problems. 2-3 hours later it started after about 8-10 seconds of cranking. Next morning, same story as the first time. Finally have it narrowed down to the 1 & 3 injector lines. They're both leaking a drop or two of fuel every 20-30 seconds while running. I've loosened & re-torqued both line nuts and still leaking. Other than the crossover tube o-rings, is there anything else I should consider as the cause of this? I'll be headed to cummins wednesday to pick up a set of six of them. Going to replace all of them at once. I have a part number of 3882589 if anyone is interested to know.

Thanks

Craig

 

[Vaughn MacKenzie]

Craig, leaky injector lines at the crossover tubes has been discussed in previous TDR magazines and posts, but one of the fixes is "polishing" the rounded ends of the lines a little with fine (1000 grit) sand paper to clean up any debris or imperfections, then reseat them. Also per Cummins the proper torque is pretty important and that too tight can cause problems as easily as undertorquing them. The proper torque is 30 ft/lbs, which would require a crow's foot end on a torque wrench but is a little challenging maneuvering around the injector lines.

 

[firefighter_2000]

Would it be better?

Would it be better to start with that instead of going the o-ring route first? Or would replacing the o-rings be a good preventative maintenence thing while I have everything apart?

Thanks

Craig

 

[Vaughn MacKenzie]

The O-rings are only there to keep engine oil from leaking out, they aren't involved with sealing the fuel system and wouldn't have anything to do with your issue.

You could also have a faulty overflow valve on you injection pump that is letting fuel drain back, but I would start with your injector lines.

 

[firefighter_2000]

Since I'm getting a drip of fuel out of the 1 & 3 line nuts I'm guessing that's where my problem lies. I'll take it all apart tomorrow and see if I can't polish up the ends end re-torque everything the way it's supposed to be and see what happens.

 

[BDahm]

I had the exact same issue about a year ago. I checked the crossover tubes and found a bad o ring. I know somebody said that doesn't seal the fuel but it was either a coincidence or the tube just needed to be reseated. But replacing the o rings defiantly fixed my identical issue.

 

[dkoldno7]

no,or long start---------------

I had about the same issue ,it turned out too be the return line gasket on the back side of the head . hopes this helps . dk

 

[firefighter_2000]

Drove the truck tonight and when fueling up I could smell fuel pretty strong. Popped the hood and found fuel leaking from the center of the nut at the head on cylinder number one. It's run down the head as far ad cylinder number 3. Going to take all the lines and tubes off tomorrow and try polishing the crossover tubes with some fine grit sandpaper, clean things up a bit and re-torque everything to see what happens. I'll try and post results in the next few days.
Thanks
Craig

 

[grimesja]

If the fuel is leaking out the nut, my bet is you have a cracked flare on the fuel line. I have had to replaces my fuel lines because three of them have cracked over time.

 

[Vaughn MacKenzie]

Check firefighter's follow-up thread here, the ball ends of the lines were quite corroded and a little sandpaper fixed 'em right up: https://www.turbodieselregister.com...998-5-2002/227669-wasn-t-crossover-tubes.html