We have a 04 ho with 30 000km at the shop and the "drivers" complained of fuel filling the crankcase....about 4 liters over in 2 - 300km. I happened to notice the filterminder missing and opened the air cleaner box to find that the filter was sucked half way into the tube and it was plugged with enough dirt to plant potatoes. We changed oil and filter , but it overfilled the crankcase again . It runs fine , but i think they're going to have to pay for some rings.....I don't know what else would cause this ?

 

sticking injector will fill the crankcase with fuel...

 

But it's running smooth....no long crank time. Have not checked for excessive blow-by yet. I hope its an injector.....we don't have time for an engine overhaul.

 

injectors sticking , seen this exact symptom at my shop.

 

I did a search (should have done first) and i found on the forum that there is a problem with some injectors leaking inside the valve cover...will pull off tomorrow....if we have time.

 

I cant see any injectors leaking , I even phoned the tech line and the say that i should see fuel spraying from the bad injector. I put lots of dye in the fuel , cranked up the rail pressure and still no luck.

 

injector could be dribbling fuel down inside the cylinder... a little exploritory surgery might find which injector is bad... if you have a borescope, you could pull the injectors and inspect the cylinder with the bore scope through the injector hole... burn pattern on the piston and liner cross hatch will be different on the dribbling one if it is an injector nozzle leaking.

 

Just replaced an entire short block due to an injector leaking at the top. destroyed the motor!

 

using dye can be a tough one to find sometimes , just better to remove all six injectors and replace the o-rings and most likely you will find one is cut or eroded thru and allowing the return side fuel to leak back into the engine. remember the pump could also be leaking fuel back into the gear area also. you wont find that with a blacklight.

 

The engine has no miss and sounds normal, so it shouldnt be "dribbling fuel down inside the cylinder" . I am going to get the inj pump pulled off to hopefully see something leaking there. If there was a bad o-ring I would think we should see diesel pouring up from the o-ring area.

 

It is the injection pump; there is a weep hole and its out of there full throttle.......kind of that they would design weep hole that leaks into the crank case..........kaboooom!