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Just wondering how everyone is doing? Me? Just driving mine, no plans for any upgrades, I guess I need to start thinking about paint,and re-plumbing the power steering system with hard piping and stainless steel braided lines.
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Re: What's the latest?
Posted by:
JimmieD
(66.81.29.---)
Posts: 1,090
Posts: 1,090
Date: May 31, 2013 09:41PM
Had a problem come up with the 4BTA in my Town Wagon, developed a fuel leak. A little 'How To' here for my Cummins cousins. Bosch VE mechanical injection has a fuel return line carrying unused fuel from injectors and also extra from injection pump back to the tank. I think all including the most sophisticated computerized fuel injection have such a return line.
On the 4BT's & 6BT's it's a sort of manifold made up of 3/16" OD fuel line sweat soldered into banjo fittings with hollow bolts threaded into each injector linking them together. This runs to a tee fitting at driver's side corner of cylinder head where I/P return line connects in, then back to tank. #2's banjo was dripping maybe once every 1-1/2 to 2 seconds, screwing the mileage, stinkin' of raw diesel and dumping fuel right next to hot exhaust manifold. Not altogether good.
Yesterday I tried a new special Cummins sealing washer at #2 injector body. These fold over top of banjo and seal both sides for hollow bolt with one part. Fired it up and Oklahoma Crude, boys, we got us a GUSHER! Disconnected return line manifold at tee, then at each injector banjo. When I loosened #1's hollow bolt the whole 3/16" line just dropped, broken clear through! Cummins West is 70 miles away, it's mid afternoon, cash flow non-existent, no idea of part number or if Cummins even had one in stock!?
Prayed a whole bunch. Drilled out the old line in banjo fitting, first about <1/16" deep with a .186" bit, then finished with a .172" bit, stopping just before breaking through to leave a tiny bit of old line at inner edge of banjo, that so my soldering brass wouldn't flow into insides of banjo fitting and plug it up. Tried for very precise angle. Threw the piece from #1 banjo/return line in the vice and clamped in a couple of places to slightly straighten it and sorta stretch it out, to make up for lost length at break. Tried to add about 1/4" to length but maintain precise angles.
Ignition points file to dress & bevel tip of broken line, polish sides. Put some acetone in a tuna fish can [no tuna] and dipped and tipped to flush out any old diesel. Where return manifold connects to tee there's a rubber gasket so care required with acetone. Clamped main return line manifold in vice, used wire to fixture #1 return line in drilled hole, again at precise angle.
Broke out the vintage Purox acetylene torch with a small #2 tip, hot dipped my 1/16" brass in flux, pressed very tip of rod against joint. Scary 'cause some very thin steel here and angles must be EXACTLY right when done for reinstall. Small flame applied ONLY to 3/16" line and about 1/8" away from banjo joint. Heated about 3 seconds, tubing metal went red, 'PPFFFTTT" and a puff of smoke and end of rod disappeared.
Prayer must have been heard because in 50 years of LOTS of copper/brass sweat soldering as hobby and on the job etc. it was the single finest brazing job I've ever done! PERFECT - downright unbelievable - YEE-HAAAAW! Thank You! All angles turned out perfect too. Amazing. Not only that but guesstimate adjustments to lengh of broken line turned out perfect too! Astounding. Lightly dressed sealing face with ignition points file. Reinstalled with new sealing washers, fired it up - bone dry, baby! How very excellent and a good day was had.
On the 4BT's & 6BT's it's a sort of manifold made up of 3/16" OD fuel line sweat soldered into banjo fittings with hollow bolts threaded into each injector linking them together. This runs to a tee fitting at driver's side corner of cylinder head where I/P return line connects in, then back to tank. #2's banjo was dripping maybe once every 1-1/2 to 2 seconds, screwing the mileage, stinkin' of raw diesel and dumping fuel right next to hot exhaust manifold. Not altogether good.
Yesterday I tried a new special Cummins sealing washer at #2 injector body. These fold over top of banjo and seal both sides for hollow bolt with one part. Fired it up and Oklahoma Crude, boys, we got us a GUSHER! Disconnected return line manifold at tee, then at each injector banjo. When I loosened #1's hollow bolt the whole 3/16" line just dropped, broken clear through! Cummins West is 70 miles away, it's mid afternoon, cash flow non-existent, no idea of part number or if Cummins even had one in stock!?
Prayed a whole bunch. Drilled out the old line in banjo fitting, first about <1/16" deep with a .186" bit, then finished with a .172" bit, stopping just before breaking through to leave a tiny bit of old line at inner edge of banjo, that so my soldering brass wouldn't flow into insides of banjo fitting and plug it up. Tried for very precise angle. Threw the piece from #1 banjo/return line in the vice and clamped in a couple of places to slightly straighten it and sorta stretch it out, to make up for lost length at break. Tried to add about 1/4" to length but maintain precise angles.
Ignition points file to dress & bevel tip of broken line, polish sides. Put some acetone in a tuna fish can [no tuna] and dipped and tipped to flush out any old diesel. Where return manifold connects to tee there's a rubber gasket so care required with acetone. Clamped main return line manifold in vice, used wire to fixture #1 return line in drilled hole, again at precise angle.
Broke out the vintage Purox acetylene torch with a small #2 tip, hot dipped my 1/16" brass in flux, pressed very tip of rod against joint. Scary 'cause some very thin steel here and angles must be EXACTLY right when done for reinstall. Small flame applied ONLY to 3/16" line and about 1/8" away from banjo joint. Heated about 3 seconds, tubing metal went red, 'PPFFFTTT" and a puff of smoke and end of rod disappeared.
Prayer must have been heard because in 50 years of LOTS of copper/brass sweat soldering as hobby and on the job etc. it was the single finest brazing job I've ever done! PERFECT - downright unbelievable - YEE-HAAAAW! Thank You! All angles turned out perfect too. Amazing. Not only that but guesstimate adjustments to lengh of broken line turned out perfect too! Astounding. Lightly dressed sealing face with ignition points file. Reinstalled with new sealing washers, fired it up - bone dry, baby! How very excellent and a good day was had.
