Fuel leak

[Leithal]

I have a slight fuel leak where the fuel joint goes into the injector pump assembly. When I took it apart I saw there were two crush washers here. Didn't see them in any parts diagram I've looked at. So could the be the cause and need to be replaced or are they not supposed to be here in the first place?

 

[VictorW]

The bolt itself is called a banjo bolt. It let's fuel pass through it. You'll find these on some of the hydraulic lines also but rubber o-rings are normally used there. So yes, those compression rings need to be on each side of that fuel fitting to seal it against the head of the banjo bolt and the injector pump. Not sure why those rings don't come up in a parts diagram. Maybe just call a dealer.

 

[xcgreene]

You can also find those copper crush washers at any autoparts or most hardware stores. just bring one in and they can match it.

 

[DLTTrekkers]

Get dowtywashers...the steel ones with the rubber inserts in it !

 

[Leithal]

Thanks for the quick replies, picked up a couple from Napa this morning. Been working in the garden since, gonna install later tonight.

 

[Grateful11]

Get dowtywashers...the steel ones with the rubber inserts in it !

Interesting, never heard of them. I like the concept. Thanks for sharing.

Dowty washers
Bonded seal - Wikipedia

 

[PILOON]

Most crankcase drains also use those crush washers.
As said most auto parts stock them.

One oil change ago I did not have one on hand so what I did is make one from some poly plastic and that worked just fine for me.
I did check often 'til next oil change. (I now keep spares on hand)

 

[caver]

Old thread response
Well I have to at least replace the back washer after today. I also could not find the washer in a parts diagram after I got home. This is the first time I've changed the fuel filter in my DK40HSE. The owners manual mentioned bleeding it but it wasn't clear to either loosen the bolt or take it all the way out. Curiosity got the best of me and I took it all the way out. Oh, I see and went to put it back together. What I didn't see was the rear washer has slipped out enough to just catch one edge of the fitting. I thought the bolt felt slow to tighten. Fuel running out when cranking it over told me something was askew. Taking it apart I then saw the back washer just catching the edge of the fitting. I got it back together and running but it's weeping fuel. Sadly it's over 100 miles away so another trip and now I wish I had taken the washer out to bring home with me.

 

[holeycow]

Old thread response
Well I have to at least replace the back washer after today. I also could not find the washer in a parts diagram after I got home. This is the first time I've changed the fuel filter in my DK40HSE. The owners manual mentioned bleeding it but it wasn't clear to either loosen the bolt or take it all the way out. Curiosity got the best of me and I took it all the way out. Oh, I see and went to put it back together. What I didn't see was the rear washer has slipped out enough to just catch one edge of the fitting. I thought the bolt felt slow to tighten. Fuel running out when cranking it over told me something was askew. Taking it apart I then saw the back washer just catching the edge of the fitting. I got it back together and running but it's weeping fuel. Sadly it's over 100 miles away so another trip and now I wish I had taken the washer out to bring home with me.

just anneal those washers; heat them red with a propane torch and quench them in water. Then they will be soft again to crush properly. That is, if the washers are not too deformed. I would probably make a couple out of a piece of copper tube or something to save a two hundred mile trip..

split it, open it, flatten it, drill it, trim it, heat it, quench it, and voila, crush washers. Crude but real.

 

[caver]

Nice to know, thanks holycow.

 

[holeycow]

You’re welcome

Many of us have had annoyances when trying to reseal things like fuel lines or hydraulic lines. I hope you get your leaks stopped!

Trying to use hardened crush washers rarely works well. Annealing them usually makes them reusable.

Regards

 

[caver]

The annealing did the trick, fingers crossed !!

 

[PILOON]

just anneal those washers; heat them red with a propane torch and quench them in water. Then they will be soft again to crush properly. That is, if the washers are not too deformed. I would probably make a couple out of a piece of copper tube or something to save a two hundred mile trip..

split it, open it, flatten it, drill it, trim it, heat it, quench it, and voila, crush washers. Crude but real.

I have also experienced that problem and my 'work around' to replace crush washers was to fabricate a replacement from polyethylene plastic sheeting I had on hand.
Again soft aluminum can also substitute for a crush washer.
Another source is the local auto parts that will probably have an assortment of suitable crush washers. (assorted kits are available on EBay as a rule)

LOL, when U live in the boonies like I do you rapidly learn 'how to' work around and also to stock anything that might someday be useful. (if U can find it when needed)

LOL, in Canada pennies don't exist any more so I kept a handful as once annealed copper is very useful. (if I can find them)