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6.2L Diesel Engine Discuss the 6.2 GM diesel engine & associated components.

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Old 02-28-2016, 01:40 PM   #21 (permalink)
NCchevy
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Got the pump working..forgot it had to build oil pressure first. Now with the truck running the pump is running. But while laying under the truck I noticed diesel leaking under the truck at the engine. Found both rear injectors leaking. How do I remedy this because fuel and a hot exhaust manifold probably don't mix well. Also won't the injectors leaking cause air to be sucked in?

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Old 02-28-2016, 02:41 PM   #22 (permalink)
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Can you pinpoint where the injectors are leaking?

You can try:

1. tightening the injector line nuts. go easy on them. 19mm wrench
2. could be the flexible return lines. if they are long enough, you can trim off 3/8" or so from each end and reinstall.
3. on the last injector one of the return line nipples is capped. maybe the cap is cracked or came off?

Edit: if both of the back injectors on each bank are leaking, I would bet on the caps failing. If that is the case and you need it fixed today, you can try to get a length of fuel line (needs to be the right diameter) and connect the two injectors to each other across the back of the engine.

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Old 02-28-2016, 02:45 PM   #23 (permalink)
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Do the flexible return lines just pull off they seem to be on there really well. The entire injector body is wet and with the truck idling both rear injectors have a steady drip.
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Old 02-28-2016, 02:50 PM   #24 (permalink)
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The original return lines have little clamps on them.

Updated return lines grip the nipples and just pull off. There are no clamps on these as they are not needed. With the updated return lines, the only items that need the clamps are the plugs. You can see the little plugs in the picture here: 6 2L 6 5L GM Diesel Injector Install and Return Line Kit 6 2 6 5 | eBay
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Old 02-28-2016, 03:20 PM   #25 (permalink)
NCchevy
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OK here is what I found. Rear most injector on drivers side of engine was loose, tightened and that one stopped leaking as far as I can tell. The plug on rear most passenger side was dry rotted and that little clamp made me invent new cuss words. My next dilemma is that the plug is extremely dry rotted and unusable. Any suggestions on a temp plug so I can get to a parts store. Oh and warn someone when fuel is gonna pour nonstop lol I was not prepared for that
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Old 02-28-2016, 04:34 PM   #26 (permalink)
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Quote:
Originally Posted by NCchevy View Post
The plug on rear most passenger side was dry rotted and that little clamp made me invent new cuss words. My next dilemma is that the plug is extremely dry rotted and unusable. Any suggestions on a temp plug so I can get to a parts store. Oh and warn someone when fuel is gonna pour nonstop lol I was not prepared for that
There is not a lot of pressure in the return line system.

You can use a short piece of return line (or correct diameter fuel line) and plug the end of it. Maybe a small short bolt with some fuel proof gasket maker to hold the bolt in the line.
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Old 02-28-2016, 04:35 PM   #27 (permalink)
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Also, injectors are tightened to 50 ft/lbs.
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Old 02-28-2016, 04:37 PM   #28 (permalink)
NCchevy
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Thanks freddyack you've been a life saver.
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Old 02-28-2016, 05:42 PM   #29 (permalink)
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Originally Posted by NCchevy View Post
Thanks freddyack you've been a life saver.
Glad to help out. I get a lot of help from DP, too
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Old 02-28-2016, 07:53 PM   #30 (permalink)
smackzed
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In a pinch your windshield washer fluid hose is about the right diametre but will deteriorate after a while. cut off 1" and push it on with a short screw as a plug in the open end. Bush league but it will get you home or to the parts store

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