Cummins ISX air in fuel return line

Discussion in 'Trucks [ Eighteen Wheelers ]' started by Pappa Bear, Nov 21, 2011.

  1. Pappa Bear

    Pappa Bear Light Load Member

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    Dec 20, 2010
    Springfield, OH
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    Hello, 06 ISX has a noise and vibration under a hard pull with some smoke. It also only gets 30 pounds of boost when it acts up like this. It will normally go up to 38. I hooked a clear 5/8 line to the fuel return and ran it into a bucket. At idle (800 rpm) the line is half air and half fuel - foamy mix. I pinched the line and the foam clears up but there is still air bubbles in the fuel. I could also feel a regular pulse in the line. I unhooked the supply line between the primary filter and the engine and ran it out of a bucket. Same amount of air in the return line. Also fuel returns quickly to the tank after engine shutdown. When I unhooked both lines I didn't get one drop of fuel.

    So, if it's an injector is there any way to isolate which one? Could it be sucking air at the primer pump or secondary filter base. I pressurized the system and did not find any leaks.
    Thank You
     
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  3. Superhauler

    Superhauler TEACHER OF MEN

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    Jan 30, 2010
    keep stroking.
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    i dont know on an ISX but if you have the return line dumping in a bucket when running you might be bypassing the pressure check valve. that might be why you have air
     
  4. Heavyd

    Heavyd Road Train Member

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    Remove suction line right at the fuel manifold and run a test line to the tank to by pass all the fuel lines, run the engine and see if the fuel clears up.
     
  5. Pappa Bear

    Pappa Bear Light Load Member

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    Dec 20, 2010
    Springfield, OH
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    Thanks I tried that and still have the same amount of air in fuel.
     
  6. Heavyd

    Heavyd Road Train Member

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    Combustion pressure is leaking up into one of the injectors. ISX injectors have a little check valve inside to prevent this. It does happen the check valve fails and you get this problem.
     
    Pappa Bear Thanks this.
  7. jmlyons

    jmlyons Bobtail Member

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    Dec 14, 2011
    erwin tn
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    Did you get the problem with your isx solved ?
     
  8. Pappa Bear

    Pappa Bear Light Load Member

    105
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    Dec 20, 2010
    Springfield, OH
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    not yet. I also noticed the fuel was getting dark. So I changed the fuel pump because I was told the seals can go bad and let oil into the fuel. So far most other people I talk to don't seem worried about the air in the return line. I would hate to change all the injectors and that not be the problem. I am running a few tanks of fuel through to see if that clears up the oil. Or is it getting dark from exhaust??? Very frustrating.
     
  9. vegetto05

    vegetto05 Light Load Member

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    Jan 5, 2009
    KC, MO
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    its is normal for air in the return side for an isx. if you had combustion pressure coming into one of the injectors, you would be experiencing engine run-on. the pulse you feel is the regulator opening rapidly. when the fuel is returned from the injectors, it reenters the fuel gear pump. only when high pressure relief valve opens does the fuel return rail returns to the tank.

    with that said, any faults? assuming the smoke is black, clogged egr dp tubes, leaking air from the signal line to the turbo vgt actuator or the actuator controller itself. if the smoke is white, you may have injector sleeves leaking coolant, but if you're not noticing a coolant consumption issue, i doubt this is the problem.

    of course, without faults, these are just suggestions. if there is fault codes, we need to start there first.
     
  10. Pappa Bear

    Pappa Bear Light Load Member

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    Dec 20, 2010
    Springfield, OH
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    There are no fault codes. I get some dark smoke when I first grab a gear, does not appear excessive. And then a little dark smoke when its pulling hard. No coolant or oil loss. No air leak in Turbo control line. New Turbo and controller. New egr cooler.1 year old egr valve. New egr temp sensor. New exhaust manifold pressure sensor. Manifold pressure and egr pressure tubes are clear. I paid Cummins $600 they could not find the source of the vibration.
     
  11. Pappa Bear

    Pappa Bear Light Load Member

    105
    22
    Dec 20, 2010
    Springfield, OH
    0
    I took a fuel sample today and the fuel was much clearer. So it was the fuel pump leaking oil into the fuel. I'm going to run a couple bottles of Lucas through to clean things up.
     
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