Highrlr

About two weeks ago my '02 started leaking fuel after playing around with my adrenaline on level 10. I thought it was coming from the fuel return line, but after snugging the connections up, it would not stop. Well, I finally took my truck to the local *********** yesterday out of pure fustration. The diagnosed it as the #4&5 injectors leaking. They quoted me $600 to fix it.

I got a parts quote from them. They have two "tubes" on there, part #'s 5011460AA and 5011461AA as well as a "connector" part # 5013856AA. Can you folks tell me, are those the tubes that go from the injector to the line or are they the actual lines from the VP pump to the head? And what would the connector be? My good freind is a cummins tech at a local Case dealership, he said you should replace both the line and the tube at the same time, and was not sure of what the connector would be?

Also, does anyone know where I can get these parts, possibly cheaper than from the dealership? Also, how hard of a job might this be, I am planning on doing it myself.

Boilermaker08

The fuel connector tubes connect the fuel line to the injector. The o-rings on the connector tubes often go bad, i've had to replace a few on my truck. They are easy to replace. Call your local Cummins dealer for the best price.

Highrlr

So all you replace is the o-rings? Can you reuse the lines and the connector tubes? If so, that would be awesome!

My freind is a cummins tech. He was saying that anytime they loosen or dissconnect a fuel line, the injection line, and the connector tube get replaced. Is that overkill, or is it necessary?

dozer12216

The injection line and tube both get replaced????? The reason for this would be to raise the cost of repairs. Of course if a gorilla works on units and bends tubes up, short cutting the repair. Acturall you are doing more than required. I have had turbes and lines loosened many times and not replaced. The O rings probablly should be replaced, along with the copper seals at bottom of injectors. Use good wrench and don't overtighten. That will destroy the tube.
Carefully inspect tubes for distortation at sealing end f tube, since you ave a injecor circuit leak supposedlly.

nickg

if its leaking fuel around the nut that screws into the head, likely its the o-rings on the connector tube, replace this first, then if it still leakes replace the connector tube....I've read somewhere there is a certain year truck/engine that you MUST replace the connector tubes each time, but thats all I remember, I've re-used mine numerous times and have no leaks

Highrlr

Thanks guys, this helps me some. I will definately start by replacing the o-rings and see what happens. Will the tube slide out of the head once the injection line is out of the way? Or does the injector have to be removed? The copper washers that were mentioned, I would imagine these are underneath the injector? I have been wanting to add some new injectors so maybe I will wait to do those till that time comes.

The shop he works at does seem like they have some fairly wasteful pollicies. But I thought he told me that he learned that in one of his cummins classes?

dozer12216

Replace tubes was suggested in very first training classes. Found not needed.

Mike D

I think connector tubes are around $80.00 a piece from cummins should you need to go that route.

I would start with the o-rings first. You use a small flat tip screw driver to aid removal of connector tube once injector line is out of the way. It's real easy.

PaulDaisy

Connector tubes are only replaced if they are the disposable type used on the first 1998 24 v trucks. All later ones are re-usable unless obviously damaged. I re-used mine at least three times.
Us Hohn's tip to eliminate the leaks from connector tubes, if you replaced injectors: install injectors loosely, hand tighten the clamps (or slightly tighten the clamps). Then, install the tubes and high pressure lines. This will allow the connector tubes to seat in with o-rings. Then, torque the injectors, then high pressure lines.
If you did not replace injectors, simply loosen small bolts holding high pressure lines together; loosen completely the high pressure line nuts; gently move high pressure lines out of the way just enough to clear the end of connecting tube; gently use a flat-bladed screwdriver or fingernails to pull out the connector tubes. Inspect o-rings; clean them, apply a bit of oil and re-install by hand. Make sure to seat them in until they click in place. Re-torque the high pressure lines, re-torque small bolts that hold the lines together.
I had to do this because my o-rings (brand new BTW) seeped a bit after engine shutdown.
Also, new connector tubes are $20 apiece from a Cummins dealer.

krawler-N-tow

I'm currently having the same problem after installing my second set of injectors on my truck. Unfortunetly, its the #6 injector where the line connects to the head. I"m gonna chill out for a couple days and take a look at it monday.

Highrlr

Oh yeah, that # 6 has gotta be a pain to get at!

Thanks for all the help guys. I will start by just replaceing the o-rings then and see what happens. Would it be smart to just replace all six of em right away? Or should i leave well enough alone and just do the leakers?

nickg

I'd do the leakers first to see if you can stop it before doing the others.