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Discussion Starter #1
Replacing my injectors with new BBIs and all of my injection lines appear to have rust in them. Is this normal? Should I reuse them? I picked up some really watery fuel about 30k miles ago and it rusted my fuel filter top. Truck ran great and these are the original injectors. Tips had a good bit of goop on them.

I don’t want to jeapordize these super expensive new injectors, but I also don’t want to replace my whole fuel system if this is normal!




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Discussion Starter #2



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Mike @ Dude's Diesel Performance
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I’d try and clean them up with a non abrasive rag.

If they don’t come clean I would replace them.

Buy them from Cummins direct. They’ll be much cheaper and OEM still than dealer
 

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Discussion Starter #4
I'm not re-using the injectors, just included that picture for reference. The rust appears to be all inside the lines, so not really sure how to clean them out?
 

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If you have rust in your fuel and it ever breaks free, it could right into your new injector and ruin it.
 

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If you have rust in the injector lines, and it appears that you do, I personally would replace everything back to the filter. Probably drain the tank and clean it as well as blowing out the line to be sure there is no water left in the system. I'd also be changing my filters more frequently until all the rust stopped showing up. Keep on top of the water separator as well. Cheaper to be cautious than to replace another set of injectors.
 

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Discussion Starter #7
I was afraid that was going to be the advice... I haven't had any rusty filters since I switched to the CAT UHE filter, and haven't any issues with how it runs, but i really don't like the idea of the rust going through these new BBIs..
 

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If there is visible rust inside the lines, throw them away.
Also check the rail inside, rust throw away.
Must use new connector tubes or your injector warranty is tiitties up.

Any rust in the system will show up and be trapped in those new expensive injectors, when they plug up and you send in for warranty, DENIED
 

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I'm not re-using the injectors, just included that picture for reference. The rust appears to be all inside the lines, so not really sure how to clean them out?
Protect your new injectors and pump with a FASS system there's an old thread about mine somewhere here and it still works great.
 

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TECH SPECIALIST
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Replacing my injectors with new BBIs and all of my injection lines appear to have rust in them. Is this normal? Should I reuse them? I picked up some really watery fuel about 30k miles ago and it rusted my fuel filter top. Truck ran great and these are the original injectors. Tips had a good bit of goop on them.

I don’t want to jeapordize these super expensive new injectors, but I also don’t want to replace my whole fuel system if this is normal!




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since you need to replace everything to eliminate the rust from the system, any chance you could take pics of the worst feed tube end & dump that end into a decent amount of the dex/merc atf, let it soak 24 or so hours and post a follow up pic?



what fuel are you using? (d2, b5, b20...)
 

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Discussion Starter #11 (Edited)
Playing it safe and ordered new lines, rail and "bag of parts" to replace the stuff fuel has touched in the CP3.

@steve05ram360 I will work on that today and post some pictures. I've never used biodiesel that I know of. On my normal routine, I only use the same two pumps at very high volume stations. I did a trip last winter across country and think I picked up a ton of water somewhere. I started a thread on it back then, other than changing filters though, this is the first I've done to take any of the fuel system apart.

https://www.cumminsforum.com/forum/3rd-gen-powertrain/2492121-rust-water.html
 
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Start using 0.5 oz of TC-W3 rated outboard lube per gal diesel. Walmart Supertech is the lowest cost and avail. everywhere. TC-W3 lube has extra additives to prevent water corrosion in fuel systems.
Also lubes and quiets down the injectors and CP3

ALL road diesel has en-trained water in it, even high volume stations. Comes from the pipeline system and bulk fuel storage tanks. Few stations bother with expensive centrifuge water removal filtration
 

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Discussion Starter #14 (Edited)
I use power service in every tank, have since I owned it.

The line between the cp3 and the fuel rail is the most rusty. Man this sucks. It was running really well before I took it apart. Guess it’s like blood pressure though, the silent killer. If anyone knows the CP3 to fuel rail line part number that’d be greatly appreciated. found it - 05086870AA




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jesus
don't buy from Mopar, way marked up overpriced
Go to Genos Garage.
they carry real Cummins/Bosch parts or check your local truck parts counter Cummins shop.

PS D Kleen does NOT prevent nor stop rust
 

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Discussion Starter #16
Everything so far has come from Diesel Power Products. Mostly because I find their website the easiest to use and prices good. Hopefully they send me a nice coupon cause I've spent a stupid amount there this week...

Having a hard time finding that feed line anywhere online that I trust...05086870AA
 

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Discussion Starter #17
3957079 is an alternate part number that many vendors have in stock.
 

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Discussion Starter #18
Everything should be here tomorrow except the #6 injector line. Apparently that’s on national back order. This is my daily, so that’s awesome.
@steve05ram360 here is the before ATF soak:



And here is the after:




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Everything should be here tomorrow except the #6 injector line. Apparently that’s on national back order. This is my daily, so that’s awesome.
@steve05ram360 here is the before ATF soak:



And here is the after:




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Im kinda surprised the ATF removed the rust like that.

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Discussion Starter #20
Me too. And honestly it wipes off pretty easy on the other ones. Just not sure how to clean the inside of the tube out. OR if putting it in ATF will just knock things loose to blast my injectors.

Not sure what to do about the #6 line. Looks like tis not even made anymore.
 
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