Cummins 5.9 Diesel Fuel in Oil

Replacing Injectors Cummins 5.9 Diesel Engine

Here is a question I received from one of my subscribers and since it's a common problem with the Cummins 5.9 diesel engines I wanted to post it and share it. This applies to the 2004.5 - 2007 year engines.

Question: I have been working on a cummins power generator engine Model 6 BT 5.9 G1 for some time now. The problem was with fuel leaking into the oil sump. I was gonna over haul the engine but prior to that i would like you to suggest the problems related to this. Can you please advice me on the common problems which will cause the fuel to leak into the engine sump.

Answer: Leaking injectors is the most common problem with a fuel collecting in the oil pan. If you're finding your oil level is rising this may be the problem. I usually put new fuel connecting tubes with new injectors (the Mechanic in the video calls them feed tubes). The feed tubes are indexed so you can't go wrong when lining them up with the injectors during installation. The Mechanic in the video explains in detail and makes this operation a snap.




This second video is from another Mechanic who demonstrates some important techniques when removing and installing Cummins 5.9 injectors. I love these videos because of the no frills production from technicians who have a good foothold and knowledge with this type of repair.  NOTE: Torquing everything demonstrated here to specs is extremely important.

 NOTE: Here's a  post with a link to a 15 page manual on tools required, procedures and torque specs compliments of a  Dodge Diesel Forum  member. Thanks Boys!