Massive amounts of Fuel in Oil!!!!

[TonOfDalt]

Well, as some of you may know I replaced my DS injectors... So far they have worked great. I went to Florida this weekend to pick-up a new truck bed and when I was almost there I noticed it started eating fuel like crazy!!! My mileage went from around 22-23 MPG to about 10-12 MPG, on top of that I was only seeing about 25 PSI of oil pressure. My first thought was to check the oil and there it was.... filled with Diesel!!!! I was in a tight spot being Saturday and 1050 miles from home with what ended up being just enought money to make it home. I had no choice but to change the oil in a autozone parking lot and then limp it back home. (had to change it again about half way home). With fresh oil I am seeing 65-70 PSI again and no power loss/overheating so I know I didnt scorch the bearings (TOUGH MOTOR :thumb I did however manage to make the rear seal crap out as it steady streams fuel/oil out of the bellhousing while idleing.
Currently I have the DS tore back down but I dont see any leaks and it appears that my new injectors are holding up as they barely drip any fuel out of the return hole while idleing. I am getting ready to start tearing down the PS but wanted to ask if anyone has ever seen a leak this severe??? I am draining about 8 gallons of fuel into crankcase every 200 miles. CRAZY!!!
Just wanted to see if anyone had suggestions on what to examine real close and where. So far the DS return line doesnt seem to have any cracks that I can see but I plan on checking it with a vacume gauge to make sure. Is it possible that by replacing just the DS injectors I have put enough fuel pressure on the failing PS injectors to cause something this severe???
Thanks for any suggestions and I will be sure to update on the progress. Oh yeah, also... I am not seeing any low pressure codes so I know its not on the Pressure Side.

 

[AubleAK]

Seems like a lot of fuel. Maybe return line under the valve covers are leaking. Seen that once before.

 

[TonOfDalt]

Yeah, that's what I'm hoping for... Driver's side seems fine, I'm tearing down the passenger side now.

 

[TeaBagger2006]

When you have the valve cover off reconnect the ficm and fuel lines and fire her up. If that doesn't show you where the leak is at then disconnect the fuel pressure regulator and check again.... Remember this is without the valve covers on

 

[TonOfDalt]

V

When you have the valve cover off reconnect the ficm and fuel lines and fire her up. If that doesn't show you where the leak is at then disconnect the fuel pressure regulator and check again.... Remember this is without the valve covers on

Yeah, that's what I did on the driver's side, didn't see anything much but its hard to tell when the oil is so diluted with fuel. While I was at it I tested the new injectors for return and they didn't have much but its hard to be accurate when at idle I can't get anything past 3-4000 psi of rail pressure.... No matter what I command or if I unplug the regulator it doesn't change. Still tested them anyways and plan on comparing them to the passenger side. I have a new LBZ pump coming Wed.
I got the passenger side just about tore down and I will update with what I find... Hoping I fire it up and its obvious as an elephant in the room. We will see.

 

[TonOfDalt]

Got the passenger side tore down and ready to test but I need to get a 1/2" Barb fitting so I can connect the fuel lines to eachother (bypassing the FICM and fuel filter assembly).
Going to head to Lowes first thing in the AM to do that and test.... After that I am ordering whatever I need.
Quick tip/tool.... I sacrificed a banjo bolt and sawed the head off so I could screw it into the injector return port and easily attach a clear line to it. Works great!
Cant wait to test and post the results!

 

[TonOfDalt]

Well... My passenger side injectors are definately bad! LOL! One injector is flowing return in the amount of cups/minute! It actually comes out with enough pressure to clear the head completely and land on the fender well! Two others where about half as bad and the last and best one was still flowing about 20 CC's/15 seconds. No wonder I couldnt build more than 3500-4000 PSI while ideling and 14000 tops at off-idle! :roflmao:
I am guessing that the PS was leaking so badly that it was actually pressurizing the return system and caused fuel to push out those crapy return line seals. That brings me to my next question... Has anyone tried to use Fuel Grade O-Rings to seal the return line??? I am going to make a new thread on this now....
Thanks guys!

 

[TonOfDalt]

Ok, so I finished doing the other 4 injectors and I am still getting fuel in the crankcase... No cracks in the return lines, brand new seals on the return lines, 8 new injectors, new CP3.... I am at a loss... I dont know what I should do next... The only thing I can think to do is vacuum check the return system. Can anyone think of anything else it could be? I torqued the return bolts to 15 lb/ft as spec, the engine fires right up now without any injectables.... I can command and hold 26,000 rail. (LBZ Pump)... I just can't seem to think of where it could be coming from....

 

[TonOfDalt]

I guess another way to find where its coming from is to pull the top half of the valve covers and pour some dye into the tank while its running and sit under the hood and wait...

 

[blk smoke lb7]

Possible cracked injector body and you checked the ballance rates with a tech 2 or a efi live V2 to see if an injector is stuck open ?

 

[TonOfDalt]

Ok... So I poured some fuel dye into the fuel filter and spun her back on... Started it up and within seconds found dye coming out of the front two injectors around the return line on both top and bottom seals... The back two looked clean... No dye.
I have had enough with these seals... Perhaps the ones I am getting are crap and do not have enough coating on them to properly seal but this is twice now with brand new return seals.... I am going to try giving them a little more torque to see if it shuts the flow off but I think I may just go ahaead and try the modification to the return line that I have been wanting to do all along.
I feel a ton better today after sleeping my anger/frustration off... I had to remind myself that now I have an engine with 8 good injectors and a new LBZ pump that fires right up instead of having to shoot butane into it every time I started it and that this is a minor problem that causes a big headache... Just need to fix it and be done. :thumb:

 

[TonOfDalt]

Also, for anyone following both my threads... I am posting this to the other thread as well so just ignore one of them.
Thanks again