IH 544 leaking fuel from return line

philcaseinWPA · Jun 13, 2022

my IH 544 hydro diesel is leaking fuel from the fuel return line. The picture shows the drip just coming off the number one cylinder. I am supposing the line is plugged and needs blown out. The line is crimped onto the injector top and I'm not sure or how to disconnect this without messing something up. Thanks for any ideas.

Phil

JimB2 · Jun 13, 2022

Those lines always leak after so many years and they leak even more in cold weather.
Replacements are available from CIH parts.
There were different part numbers for the D-239 Engine depending on serial number and application.
This is the low pressure return line or often called the leak line.

wore out · Jun 13, 2022

(quoted from post at 08:00:40 06/13/22) Those lines always leak after so many years and they leak even more in cold weather.
Replacements are available from CIH parts.
There were different part numbers for the D-239 Engine depending on serial number and application.
This is the low pressure return line or often called the leak line.

To add to what JimB2 said, the line appears to be Part #3055606R91.

It has a ''banjo fitting'' at each injector and two #710673R2 sealing washers are needed at each injector.

caterpillar guy · Jun 13, 2022

We used some return line with those pinch clamps for each injector without the crimped ends. Just cut the crimp off the outside to get to the barb have had less leak problems since we did that. Those lines from dealer are expensive. Last one we got was something like 50 dollars back in the 80's or 90's. Probably more like over a 100 now. I think we got the return line from local parts house.

jm. · Jun 13, 2022

Like CP ssys you will be making you a new line once you go price the new factory one, IF you pull the DRIP line as it is called off be sure and use new washers when you go back or risk more leaks.

philcaseinWPA · Jun 13, 2022

So there is barb under the crimp? Does the crimp just pull off the barb or need cut off? On my 885 the hose was just pushed on and I just used some clear Tygon tubing I got from the lab where I worked. Still working.
Phil

jm. · Jun 13, 2022

Depends on which line you have, if it is like old fabric you have to take a die grinder and split that small brass collar if it is rubber most times they will pull off

JimB2 · Jun 13, 2022

My brother did the same as Caterpillar Guy suggested, bought some fuel grade plastic line and hose clamps at the auto parts store, cut the crimps and pulled the old lines off.

IH 544 leaking fuel from return line

philcaseinWPA

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JimB2

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wore out

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caterpillar guy

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jm.

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philcaseinWPA

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jm.

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JimB2

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