3rd Gen Engine and Drivetrain -> 2003-2007 5.9 liter Engine and drivetrain discussion only. PLEASE, NO HIGH PERFORMANCE DISCUSSION!

Rebuilt engine fuel leak

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Old Sep 12, 2013 | 01:19 PM
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From: Austin TX
Rebuilt engine fuel leak

I just put in a rebuilt motor. it didnt fire up initally. Turned out #4 fuel line was leaking like a seive. i replaced it with a new one from Cummins. only $24!! Dealer wanted $70! The new one has a all metal bracket and it looks pretty beefy. The engine fired up right away and was doing great for the first 5 mins. Then I started to see a pretty good fuel leak that was dripping down the tranny/ engine junction. #4 looks dry and I cant see a fuel leak from the CR. I have not checked the injectors that came with the motor ( that was going to be my next step after I got the install done). i did see a coupe of little drops going down one of the lines next to the fuel filter but not the leak that i saw earlier.

My question is this:
Is it possible it is a stuck injector and that there is a high return flow that is leaking somewhere? There was a delayed return to idle when you gave it a little fuel.
What should I do next??
Any constructive thoughts would be helpful . It has been 4 months with no truck and I would love to see her purr again
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Old Sep 12, 2013 | 06:18 PM
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From: Claxton, GA
Did you check the fuel return on the back of the head?
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Old Sep 12, 2013 | 08:12 PM
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leak is most likely on the low pressure side, since a leak on the high side would cause a no start or the fuel would be misting,
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Old Sep 12, 2013 | 09:05 PM
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Where do I find the return hose? Do I need to crawl up under the hood to find it? Is it safe to drive it to the dealer leaking?
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Old Sep 12, 2013 | 10:29 PM
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From: Claxton, GA
It is on the very back of the head. I you have injector leak due to a bad injector or crossover tube seal, this will return the fuel to the tank. It's a banjo bolt on the back of the head. They may have left a copper washer off.
It's not the PRV valve on the rail.
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Old Sep 12, 2013 | 10:36 PM
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From: Claxton, GA
Here is a picture if I can get it to post. See it at the back of the engine.

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Old Sep 12, 2013 | 10:45 PM
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From: Claxton, GA
Little better pic.

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Old Sep 14, 2013 | 12:18 AM
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Thanx for the picture! turned out the #6 fuel line was the culprit. Now no more leaks. dNow I am just puffing lots of blue smoke Not sure what to make of this yet. Truck runs great ( or so it seems). no error codes. Any ideas? Head was rebuilt and I was told new rings were placed.
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Old Sep 14, 2013 | 11:48 AM
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From: Claxton, GA
Check your turbo's seals. I would also call the folks who rebuilt it. Did you install it, or someone else?
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Old Sep 14, 2013 | 02:14 PM
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I had called the guy who rebuilt it., he said he put new bearings in and new rings. i had a guy install the motor for me. how do youcheck the turbo seals??
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Old Sep 14, 2013 | 08:01 PM
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From: Claxton, GA
Just pull the air cleaner intake off and look inside at the compressor wheel. To inspect the exhaust side you will need to pull the downpipe off.
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Old Sep 24, 2013 | 12:53 PM
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when i pull off the air cleaner and te downpipe what will i be looking for?
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Old Sep 24, 2013 | 06:02 PM
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From: Claxton, GA
Originally Posted by Txbigfoot
when i pull off the air cleaner and te downpipe what will i be looking for?
Engine oil.....
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