bad brandnew return line set????

[superbeetle73]

well i just installed the return line kit from pensacola diesel and within minutes had diesel and smoke all over the place. i just got out of the shower and still smell like diesel. well im glad i wasnt drivin anywhere. i thought i was havin air intrusion so figured i do the return line set. then i saw that the side of the cap blew out. any ideas as to what caused this???

 

[itsacrazyasian]

dude that looks like combustion gases passed through the injector and melted the return cap.

 

[superbeetle73]

how can this be resolved if it is that problem??

 

[itsacrazyasian]

its usually because of a stuck injector. replace/rebuild injector.

make sure the injector is sealing well in the head too. ie copper washer

 

[flareside_thun]

Does the truck run rough at all?

 

[OLDBULL8]

Surprise, you have a PSD! Power Squirting Diesel.

 

[icanfixall]

Somehow you got some dirt in that injector when you did the return lines. Now the pintle is stuck in the open position. Remove that injector and take it apart but make sure you clean it first. The pintle needle will be stuck in the nozzle head. You will need another return line cap and an injector copper gasket. Any good injection pump rebuild shop will have these parts.