Long Way from Home - Diesel Trouble

[osirissail]

Since the problem started after the injection (high pressure) pump was rebuilt and re-installed - that is logical place to start looking for an air leak.
- - The idea is that they took something off the engine and put it back and now you have air leakage somewhere, so it is logical to suspect that area of the engine first.
- - The fuel pipes leading to the injection pump sometimes have round copper washers if the attachment is what is known as a Banjo Fitting. These round copper washers are hard to come by so it is common that the installer will try to reuse the old ones. Also a tiny speck of dirt or debris lodged in the washer/gasket of the supply pipes could allow air to leak into the pump.
- - Heating and cooling of the engine will cause parts to expand and contract allows air gaps to open up when the engine is cooling. This will allow air to enter the system. Recheck the bolts/screws holding the parts of the injection pump together, some may have loosened up a little. Also the "bleeding" screw assemblies might have a speck of dirt preventing them from closing air-tight.
- - If there is an engine mounted "last chance" or CAV fuel filter the pipes coming into and leaving it are highly suspect for air leaks as is the filter cartridge itself. There are sometimes little plastic sleeves that slide over the ends of the fuel supply pipes that split and fracture during removal and replacement of these pipes. You have to use a flashlight and probe to look inside the hole where the pipes are screwed into the filter to see these little plastic collars.
- - So I suggest starting with the injection pump and inspecting or tighten each fitting/part working back to the lift pump. Most of these pipes are metal compression joints which are prone to leak if they are not installed exactly correctly or if some dirt get into the fitting.

[Tia Bu]

Many, many thanks to all of you. We checked the whole fuel supply line back to the tank. We found three loose hose fittings and, ultimately, we found the dreaded clogged tank pickup. What a chore!

It seems to be running o.k. now. We're off to the south tomorrow. Many thanks to all for your help.

[DeepFrz]

Glad you found it. Good luck on the rest of your journey.

Sounds like a good tank cleaning should go on your ToDo list.