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FC (Forward Control Unique Issues) If you have a unique issue with your FC model coach and it can't be answered in one of the other forums here, then this is where you can list it.......List your FC Parts here too.

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  #1  
Old 12-20-2009
NH Bill's Avatar
NH Bill NH Bill is offline
1983 FC 35 "Casa Billisa"
 
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Default Injector Lines Sawed by Throttle Springs

Injector Lines Sawed by Throttle Return Springs

Warning: Don’t let this happen to you!

My injector pump started leaking from the bottom seal. The symptom was fuel dripping from one of the three plastic drip tubes that extend downward to the frame from the pump. Traced the tube back to the low end of the pump…not good, pump had to come out. The leak only manifested on a cold start. Once warm, the drip stopped. So I was fortunate to have noticed it and to have a good CAT man available to rebuild the pump.

As for me, I had the pleasure of removing the pump and getting it on the bench for him. After he got the pump back in place, I had even more fun putting it all back together! (under close supervision)

While getting parts cleaned up for reassembly, I noticed the under side of two of the injector lines had pretty deep cuts in them in the same location. The cuts looked like a hack saw had a go at the lines. This was strange, but could not at first determine the cause. Although these lines are pretty thick, the cuts were so deep I decided to replace them. Called the CAT house and had them the next morning to the tune of roughly $70/each. As we were putting this all back together we were looking for what could have caused these cuts, well there it was, the throttle return springs were dragging one on top of another along the bottom of the new injector lines.

Remedy: Fitted the lines with hard plastic airline that we sliced and zip tied it on. Seems to be working just fine but will keep an eye on them.

I’m lucky the lines did not fail on my recent trip down the east coast… about 1600PSI I’m told... what a mess that would have been.

NH Bill (grateful to be Wandering… I mean wintering in Florida)
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Bill and Lisa Garamella
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2006 Jeep Liberty CRD
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  #2  
Old 12-20-2009
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Bill, Good find,
I will be checking mine as soon as I get the chance.
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  #3  
Old 12-20-2009
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Thank You Bill, Very good catch. I'll be looking at mine in the AM.
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  #4  
Old 12-21-2009
Frank W. Frank W. is offline
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Thumbs up

Thanks for a great post and the photos make it clear what to look for!
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  #5  
Old 12-21-2009
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those cuts were under the bottom of the lines,use a mirror to check for them.
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  #6  
Old 12-21-2009
fxdwg fxdwg is offline
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Bill,

Do you think the cuts are from vibration causing the spring to bounce on the lines, slowly cutting through them, or do they contact the lines and then cut through with usage?
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  #7  
Old 12-21-2009
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John,

The way mine is set up, the springs literally drag along the bottom of the injector lines. No doubt, vibration is a factor as well. That spring steel must be very hard. Kinda like a vibrating wire saw. Note however, the engine has 80K on it and I have no reason to think these are not the original lines and springs. Springs show no sign of wear!

NH Bill
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Old 12-21-2009
diesel bill diesel bill is offline
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While you have access to the damaged fuel lines, replace them. it's a matter of time before they are going to fail.
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  #9  
Old 12-21-2009
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That's exactly what I said I did.

NH Bill
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  #10  
Old 12-21-2009
diesel bill diesel bill is offline
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I saw the new lines installed. My comment was agreeing with you replacing the worn lines with new. I know how difficult it can be to access them.
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