Truck stalled going into driveway of the house, no start, just cranks. No codes. Fuel is all along the frame, tranny, and appears to be coming from the old stock fuel pump and canister area. Airdog 100 still shows 15lbs of pressure. See fuel on the fuel rail, but no real signs of a leak. Fuel line appears to be fine, no leaks when I checked it with the pump cycling. Cannot figure out where the fuel would be coming from and whether air may be getting in to the system, need immediate help

 

Only thing I can think is rp sensor is hanging, fca is sticking, or cascade overflow is messed up. return is flowing fuel back to tank, and getting fuel to cp3.

 

rail pressure relief valve looks to be leaking, has anyone had this issue, and if they hang will they leak out and keep the truck from starting?

 

Most common thing is an injector line cracked. Look at #4,#5,&#6.

 

don't see raw fuel around there, see it on the rail, around the old canister, and all under the truck

 

when the 4 th line goes it blows it everywhere. Have someone crank it while looking. dont get to close, the psi can kill you...

 

We have been looking at it all afternoon, are not seeing any wetness at the lines, but seeing it on the injection rail and below on the old canister and fuel pump, which I never deleted. Truck is dead at the moment, guess I was lucky it stalled turning in the driveway, had just made it back from a 100 mile round trip. I noticed my overhead was dropping miles on dte quicker than normal, was thinking it was from the update to the new revo, but when it stalled and smelt the fuel I knew something else was up.

Whats the chances of the rail cracking? If it were an injector line, wouldnt there be evidence of fuel on the line itself? It seems really wet around the relief valve, but have never heard of it leaking when bad.

Thanks for the help so far guys, maybe we can get this figured out.

 

i had one break on my 06, if i remember right i sprayed fuel towards the rail due to how it cracked

 

This is where a fuel rail pressure gauge would be invaluable.

Since the truck won't start and you have a fuel leak but still have 15psi low side fuel pressure, I would guess your rail pressure is leaking and is now too low for the engine to start.

You mentioned that you deleted the original fuel cannister. Did you use the Glacier Diesel cannister delete fitting? The stock fuel cannister is chambered and all 3 fuel returns go to and thru it and back to the fuel tank.
The return chamber are separate from the feed circuit to the filter and then out to the CP3.

If not how did you handle the 3 fuel returns that the common rail Cummins have?
I would guess that your rail pressure release valve has failed and is now bypassing fuel into the return which is leaking.

 

Thanks rich, I will look again tomorrow, we cranked on her quite abit this afternoon, couldnt see any additional traces of fuel, pulled the banjo bolt on top of the relief valve and seen bubbling at first, then small seeping, but nothing else.

Sure wish my quad rp guage worked, I keep it n the truck as a reminder never to buy another quad again.

 

Didnt delete it, its still mounted along with the stock pump. The canister is dry. Only thing I plugged was the old 3/8 fuel line from the stock pump, all the returns werent touched

 

You need to determine if that fuel is coming from the pressure relief valve or from the the Cp3 return line.

Bend the line at the top of the PRV away slightly. This will determine where that fuel is coming from.

Glacier Diesel has a fitting that replaces the PRV banjo bolt and isolates the 2 returns.
http://www.glacierdieselpower.com/pr...spx?pf_id=9013


At idle, there should be NO fuel bypassing the PRV. If there is, your PRV has failed. It is bypassing rail pressure which is why the engine won't start.

 

Awesome info, will be the first thing I check when I get off work tomorrow. Im thinking the relief valve has failed, as there seems to be more wet fuel in that area than by the cp3 return. Will get back with you all tomorrow

 

Got a new fca from dealer, couldnt get the arson from Shane, he said he didnt know when he'd have any in stock again. Called Industrial Injection and they were out of their kit, backorder on fcas til next month.

Out of curiosity I priced the relief valve at my local dealer, $600, I was at a loss of words when he told me that price. So I called Andy at Genos Garage and got the fuel rail manifold, relief valve and rp sensor shipped for $317. Cummins part and Andy was great to deal with, awesome customer service. Hope that and the fca will get my truck back up again. Havent had a chance to look at the truck today, we actually got alot of rain for once