Hi all,

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Tuesday afternoon I was getting on the truck a little bit when all of a sudden it had a noticeable loss of power. Not bad, but a noticeable loss. I pulled in to the house and there was a smoke coming out from under the hood.

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Apparently I blew off the little “cap” that covers the return line nipple on the back of the right rear injector, and the line off of the front injector where it connects to #2. Replacing the little cap was a pain (fat fingers & tight space), but I got it done and put the #1 line back on. I clipped the line a little so it would have fresh rubber gripping the nipple.

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My questions are:

Is this a fairly common problem? Should I keep “spares” in the glovebox?

What would cause this?

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FYI: I do have a new injector pump and I have no idea how old the injectors are. I was planning on replacing them (just to start with a clean slate), but I haven’t gotten around to it yet.

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Thanks,

- Shawn

Sounds like the return line has a restriction in it of some sort, either plugging off or the return line itself has been pinched somewhere. Is the injection pump a recent install? Follow the return lines and make sure they aren't pinched anywhere.

Was there a clip on the cap? I don't use the PITA clips on the return lines, but I do on the dead-end caps at the rear of the heads. As mentioned, look for any pinched lines in the return system.

The injector pump has been on for around 2 weeks and I am not sure if the cap had a clip on it or not. The new one does (and it was a PAIN!).

I will check the lines for kinks / obvious restrictions tonight but in the meantime, I am afraid to really get on it. If this happened with the wife driving, she would have dumped 30 gallons of diesel on the road on the way to get groceries.

- Shawn

Kennedy sells clipless return lines.

Dipaco makes them, DPE65110 or 120, one is the pump kit one is the injector kit, I know 100 is both together with manifold gaskets.
They come with braided hose that doesn't need clips on the hoses, but still comes with 2 for the caps.
Just about any fuel shop out there carries them.