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· Registered
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Discussion Starter · #1 ·
Hi guys, new to the forum here. I just bought a 2006 3500, and started to notice some diesel smell when shutting the truck down and hopping out. Couldn't see a leak anywhere visually, so I kept running the truck and doing research.

Fast forward a couple weeks, and I've got fuel leaking from what appears to be the #3 or #4 injector supply line. Ok, no big deal, I read the #4 injector supply thread so I bought the lines from cummins and swapped both out. Fired up the truck, and still have a leak! It appears to be coming not from the line, but from the #3 crossover tube (where it threads into the head).

So i guess my question is, is it common for a leak to appear there if a tube is cracked? Am I risking doing any serious damage buy running the truck with it leaking there? Just heard some horror stories about these trucks when they have injector issues and I'm still learning the engine.

I couldn't really get my torque wrench on the tube, but it felt snug. I backed it off a tad with an open-end and snugged it back up but it still leaked afterward. Truck seems to be running just fine, and its not leaking like crazy or anything, but it does leave a small puddle and is getting worse as time goes on.

I'll be calling cummins and making an appointment but I don't want to blow this thing up beforehand haha. Whattya think?

Thanks for any help in advance!

· Premium Member
9,169 Posts
Hopefully they checked all of them and followed procedure to retorque connector tubes/injectors.
1. Inspect fuel injector:
a. Look for burrs on injector inlet.
b. Check nozzle holes for hole erosion or plugging.
c. Inspect end of nozzle for burrs or rough machine marks.
d. Look for cracks at nozzle end.
e. If any of these conditions occur, replace injector.

2. Thoroughly clean fuel injector cylinder head bore. Blow out bore hole with compressed air.

3. The bottom of fuel injector is sealed to cylinder head bore with a copper sealing washer (shim) (1) of a certain thickness. A new shim (1) with correct thickness must always be re-installed after removing injector.
Measure thickness of injector shim (1).
Shim Thickness: 1.5 mm (.060”)

4. Install new shim (1) (washer) to bottom of injector.
Apply light coating of clean engine oil to washer. This will keep washer in place during installation.

5. Install new o-ring to fuel injector. Apply small
amount of clean engine oil to O-ring and injector bore.

6. Install injector into cylinder head with male (high pressure)
connector port facing the intake manifold.
Push down on fuel injector mounting flange to engage O-ring and seat injector.

7. Tightening Sequence:
a. Install fuel injector hold down clamp (mounting flange) bolts. Be sure the clamp is perpendicular to the injector body. Do a preliminary tightening of these bolts to 5 N·m (44 in. lbs.) torque. This preliminary tightening insures the fuel injector is seated and centered.
b. After tightening, relieve bolt torque, but leave both bolts threaded in place.
c. Install high-pressure connector and retaining nut. Do a preliminary tightening to 15 N·m (11 ft. lbs.) torque.
d. Alternately tighten injector hold down bolts to 10 N·m (89 in. lbs.) torque.
e. Do a final tightening of the high-pressure connector and retaining nut. Tighten to 50 N·m (37 ft. lbs.) torque.
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