Beware! Leaking Injector Pipe Connections.

Beware! Leaking Injector Pipe Connections.

Postby Mitstech2936 on Sun Sep 23, 2012 9:13 pm

Just a heads up to any of you who are not aware to this problem,
if you own a 4d56 or 4m41 (2.5 & 3.2l) they have the commonrail diesel injection pipes pass through the rocker cover to the injectors from the fuel rail...
If you ever experience the engine
Chugging
Missing
Lack of power (substantial)
Or u feel sumthing is a miss in general especially just after a 30,60,90,120 etc interval service
Have a good look at your engine oil level and take note of it, if it rises or oil smells like diesel fuel (raw) then under no surcumstances should you start it or drive it to even get looked at or fixed,
If the oil level rises and smells like raw diesel there is a leak at the injector pipe to injector and it's pumping raw diesel straight into the engine, two reasons why this is really bad to drive it
1. Can haudraulic the engine
2. The diesel fuel will escape out your breather in rocker cover and gets recirculated straight back into the intercooler, as diesels basically have constant air going through them and they are regulated by revs via the diesel pump you can experiance a (full throttle) sensation and in extreme circumstances turning the ingnition key off won't even stop the engine from powering on at full revs, (very bad if vehicle is moving) worse case senario if stationary would be conrods hangin out the block, the diesel injection pipes have a specific tension they are meant to be torqued to and if any of you do your own valve clearance services then I be more than happy to pass on any knowledge I know in this area just pm me
Last edited by daryn on Mon Sep 24, 2012 7:42 am, edited 1 time in total.
Reason: title edited to better reflect topic subject
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Re: Beware!

Postby drillbit7 on Sun Sep 23, 2012 9:48 pm

Great post Mitstech, you obviously know what you're talking about.

Just to add to it a little. This problem can also cause low oil pressure. (Had a very similar problem in a 6V92 Detroit engine) So if anyone does have an oil light come on, then after you shut the engine down, pull the disptick out and give it a sniff. You'll very clearly smell diesel if that's what's happening.

Once again, great post Mitstech... A good thing to bring up.

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Re: Beware!

Postby T-TRUCK on Sun Sep 23, 2012 9:53 pm

Wow!! Really not a good thing to have happen!! Mines due for its 90 service very soon and I've noticed my oil is black as and smells kinda burnt... Is that what you mean?? :? (Stressing much)
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Re: Beware!

Postby Mitstech2936 on Sun Sep 23, 2012 10:05 pm

Yea drillbit low oil pressure too

And t-truck the burnt smell is normal, you will know about it if it is happening it will usually be coupled with a nice engine surge or lack of power, but if u are ever worried just keep tabs on the oil level an if it raises drastically then it'd be time to shut her Down lol
Generally the tensioning cycles of injector pipes is 6 times, then it's time to throw them in the bin and buy new ones, but if an inexperienced person has torqued them down or not even at all or not but back in all the pipe retaining nuts then expect the life of the fuel pipe to diminish sumwhat
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Re: Beware!

Postby Mitstech2936 on Sun Sep 23, 2012 10:05 pm

Yea drillbit low oil pressure too

And t-truck the burnt smell is normal, you will know about it if it is happening it will usually be coupled with a nice engine surge or lack of power, but if u are ever worried just keep tabs on the oil level an if it raises drastically then it'd be time to shut her Down lol
Generally the tensioning cycles of injector pipes is 6 times, then it's time to throw them in the bin and buy new ones, but if an inexperienced person has torqued them down or not even at all or not but back in all the pipe retaining nuts then expect the life of the fuel pipe to diminish sumwhat
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Re: Beware!

Postby T-TRUCK on Mon Sep 24, 2012 5:30 am

Few!!! Thought I was gunna have to start sniffing my dipstick everyday for a while then!! :? That sounds abit wrong when ya think about it! :lol:
Thanks heaps for the post mate.
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Re: Beware!

Postby trickydevil on Mon Sep 24, 2012 6:29 am

Im at 177000kms and never had this problem, Thank god. BUt will keep it noted in the memory banks.
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Re: Beware!

Postby NowForThe5th on Mon Sep 24, 2012 7:33 am

Mitstech, one of the reasons why NewTriton has become the premier site for knowledge on Tritons is the solid technical expertise shared in posts like this. I'm sure that I speak on behalf of every member here when I say "Thanks for your contributions, mate". 8-) :D

So that others can find this valuable information can I just make one small suggestion? Go back to your original post and hit the "EDIT" button, then change the title of the post to something like "Beware! Leaking Injector Pipe Connections". Might make it easier for others to find this information in the future. ;)
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Re: Beware! Leaking Injector Pipe Connections.

Postby daryn on Mon Sep 24, 2012 7:43 am

I was just about to the title thingy for Mitsi 5th :D
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Re: Beware! Leaking Injector Pipe Connections.

Postby Lee-thal on Mon Sep 24, 2012 8:19 am

Just another quick note on this, Tension is not everything, Make sure that all the fittings are super clean when refitting pipes, We have seen pipes correctly tensioned but with dirt/grime on the connections and this has caused leaks.

NOTE that a DEALER should be carrying out a HIGH pressure Leak test after the service to ensure there is no leaking. This is done at much higher pressures than normal, it is done via the MUTIII

Cheers Lee
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Re: Beware! Leaking Injector Pipe Connections.

Postby Mitstech2936 on Mon Sep 24, 2012 9:41 am

Thats alrite :)
And yea lethal cleanliness is next to godliness
The mutt 3 is my best mate at work that's for sure
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Re: Beware! Leaking Injector Pipe Connections.

Postby variflex on Mon Sep 24, 2012 6:24 pm

Just out of interest under what circumstances would the pipes need to be removed anyway, I cant imagine they would be removed durin regular services
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Re: Beware! Leaking Injector Pipe Connections.

Postby gregned on Mon Sep 24, 2012 6:46 pm

The pipes are removed during valve clearance adjustments.
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Re: Beware! Leaking Injector Pipe Connections.

Postby Mitstech2936 on Mon Sep 24, 2012 7:45 pm

Every 30k interval,
30,60,90,120,150,180 & replace pipes at 200
$330 genuine
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Re: Beware! Leaking Injector Pipe Connections.

Postby aids84 on Mon Sep 24, 2012 8:08 pm

Pipes are replaced every 6th time they are removed, normally the 180,000 service.

Make sure the injector pipe table in your service books are being filled out after every valve adjustment. If it hasn't been it might be worth asking why not
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Re: Beware! Leaking Injector Pipe Connections.

Postby Mitstech2936 on Mon Sep 24, 2012 10:05 pm

I thort it was 6 full usages not the 6th time?
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Re: Beware! Leaking Injector Pipe Connections.

Postby aids84 on Tue Sep 25, 2012 5:46 am

Mitstech2936 wrote:I thort it was 6 full usages not the 6th time?


Dunno just going by the chart that's in the owners service manual. We replace them at the 180,000 service.

Other manufacturers (Nissan, VW) recommend replacing them each time they are removed, but I guess they don't need to be removed every 30,000 to adjust tappets.

We also had a Triton come in with a pipe slowly leaking at the rail (service done by another dealer). The leaking diesel made it's way into the bell housing and saturated the clutch plate, rendering it useless. Obviously didn't do the fuel leakage test on that one.
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Re: Beware! Leaking Injector Pipe Connections.

Postby Mitstech2936 on Tue Sep 25, 2012 6:03 am

Yea that's pretty full on ay, iv seen a couple come back after a period of time though and the young bloke who did them at work definantly did the leak test and it held 180mpa multiple times over on the leak test when he did it. The tension wrench he was using wasn't calibrated and he didn't realize... Lack Of experience....
The pipes chatter ever so slightly on the seat until it leaks down the track... After fixing his stuff ups twice I worked out his t/wrench wasn't calibrated correctly, when I checked it against my regularly calibrated torque wrench was reading 38nm to his 28nm on his torque wrench
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Re: Beware! Leaking Injector Pipe Connections.

Postby kevin on Wed Mar 10, 2021 9:40 am

aids84 wrote:Pipes are replaced every 6th time they are removed, normally the 180,000 service.


So who can help me identify / confirm the bits needed for the replacements for a 2010 MN. I'm told there are 5 pipes so the obvious from here https://partsouq.com/en/catalog/genuine ... 40AD009794
07421 FUEL INJECTION,NO.1 Part number: 1428A044
07422 FUEL INJECTION,NO.2 Part number: 1428A166
07423 FUEL INJECTION,NO.3 Part number: 1428A045
07424 FUEL INJECTION,NO.4 Part number: 1428A034

Is the 5th the pipe from the pump 07430 Part Number: 1428A165 i.e. it's not the rail is it (I hope not)?

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Re: Beware! Leaking Injector Pipe Connections.

Postby DibbyDibbyDJ on Wed Mar 10, 2021 10:47 am

I dont think those part numbers are the current ones for the 4D56 engine.

And the 5th pipe is from the pump to the rail
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