After installing the "free washer-mod" kit the truck ran fine.
Probilly put 15-20 miles on it and I hurt a light TUT TUT TUT sound, and I was probilly about 10miles from home, pulled over didn't notice anything out of the ordaniry then I came to a stop sign and hurt POOF POOF POOF and saw white smoke rolling out from underneath the hood.
Opened it up and saw that I popped the 5th injector messed up the return line, ect..

What causes these to go? I never took the motor over 3k.

 

94-95 pumps have an issue with #5 high pressure line splitting and causing problems.

 

I would think the Injector nut had to loosen for it to physically pop the injector out of place?

 

Bill... do you have any more details on this??Is that both for the 160 and 175 pumps?

 

It's something Piers told me several years ago, said it was quite common but didn't know the exact cause.
I've personally never run into it.

 

Yea the injector nut must of came lose some how. I am trying to figure that out.
The return line broke in 2 places $93.00 from cummins and the brass clips for on the return line $3.00 a piece.

Both the threads in the head, and on the injector nut are perfect.
I did not find the washer/cup for the injector tho so I am pulling another injector and making sure when the previous owner installed the injectors he put washers in..
If not that could be the culprit of the injector going up and down during compression and I supose eventually working the nut lose.

Thanks infidel.

 

I had a fuel delivery line pop on me awhile back. leaked 25gal of diesel onto the highway near the NH/MA 93 toll plaza before I noticed the fuel missing. Turns out there is an updated part from cummins (thanks..) that has a braided section.
The high pressure line sounds like another potential trouble spot. If I remember that 160hp pump injects at a lower pressure. Anyone know what the pressures are for that and the 215? If I upgrade I may have problems. Any aftermarket lines out there with stock inner diameter?

 

You don't happen to have the Cummins part number on the return line do You? I can't get #1 and #3 to quit leaking on the return line. Tried new horseshoes, loose, tight no go. Different injectors and it still leaks so figure it is the return line. Doesn't look like it comes from under the high-pressure line. Sorry to hijack the thread. Any other thoughts on fixing the problem are also welcome.

Paul

 

No problem.
I will grab the part # tomorrow.
Any Cummins shop should be able to hook you up if you know the engine family code. 8 Digits, stamped on timing cover. Hassle to get at tho.

 

I was thinking about this #5 line splitting.Could this be the result of putting in higher flow DV?You would think the higher flow will cause higher pressure cracking the lines..Would also like P/N for these lines.Mine haven't leaked yet but would like to replace them as a PM.My high pressure line from the filter canister to the IP has already been replaced(cracked also).I guess the next line to replaced would be the return line from the injectors...Is this right??Is this the next weak spot?