Blew 4 hours on a fuel leak that was just a loose banjo bolt

I was working on a 2015 Freightliner Cascadia last Wednesday and it had a diesel leak that was driving me NUTS. The drip was coming from somewhere around the injector return line and I spent the whole morning swapping out o-rings, checking the hard lines, even pulled the valve cover twice to inspect the injector seals. After 4 hours of messing around I finally noticed the banjo bolt on the return line was barely hand tight from the last guy who worked on it. I torqued it down and the leak stopped immediately. Felt like an idiot but hey it happens. Has anyone else wasted way too long on something simple like a loose fitting?

3 comments

3 Comments

paule531mo ago

Read that one post where a guy found the same thing on a Peterbilt.

rosek441mo ago

Yeah but that Peterbilt post was about a compression fitting not a banjo bolt.

wright.kevin1mo ago

@paule53 probably saw the same thing I did, that post about the Peterbilt had a similar loose banjo on the return line too. Just one of those days where you look past the easy fix because you're already deep into the hard stuff.