How bad can I screw up the return lines?

[Sycostang67]

While going through my engine compartment, I noticed 3 leaking caps on the injectors. Looks like I'll be purchasing a return line kit, as they are all gray which means original with 118k miles. It looks like a fairly simple and straightforward process, remove injector lines, swap caps, hoses and o-rings. Going through posts and looking through the kit I see I will be relocating the crossover line to the back of the motor. I will also be changing the fuel filter while everything is apart. Is there anything I should be aware of before diving into this project. This is my first diesel, so assume I know nothing.

 

[towcat]

my trick with getting the caps to seat on the o-rings is a little dab of vaseline on the o-rings. it makes life just a little easier.

 

[LCAM-01XA]

Dielectric grease is what I use for o-rings lubrication, works good.

 

[icanfixall]

K Y... Why... Because it just works so well.... Actually any grease will work great. Use a dentel pick to remove the old o-rings and keep things really clean. Install the first o ring on the top groove. Then roll the second one over that one till it seats in the bottom groove. Make up the caps and lines using the old set for a size and press them on till you hear and feel a click. Job done. Loosen the injector line clamps but don't remove the nut and bolt. They are really tuff to reinstal. Having the lines loose will make it easier to thread the lines back on the injectors. Don't cross thread them. Its really easy to do too. I like to hand thread the nuts all the way down the injector. That way you know they are not cross threaded. You really don't need to bend the hard lines much at all. The caps will come up and off the injectors easy. Post back if you get stuck or have questions. Plenty of help here all the time...

 

[jeffgordon24]

where do you guys get the return kit

 

[towcat]

where do you guys get the return kit

pm "typ4"(russ)
he's got a screaming deal on the kits.

 

[Agnem]

I'd relocate any cross over lines to the front. Easier to see if anything is leaking there. Basically just look at your injectors and fuel filter and injection pump fuel returns, and follow the flow of fuel with your eyes. If that particular device has a way to get fuel back to the tank, then you did fine. There is no right or wrong way to run return lines as long as the fuel can get to where it needs to go.

 

[Sycostang67]

Thanks, hopefully I will get the kit later today and get this thing fixed before wednesday. I got an hour drive back to the dealership so they can fix the new windshield they had installed. It's leaking water right onto my new pyrometer.

 

[geonc]

All good info
One thing to emphasize is the clamps---make double sure the lines lie true in the grooves and be sure and re-tighten any you loosen/remove!

Those clamps are important to absorb the vibration from the fuel pulse---any missing/loose will guarantee a busted line at the nut!

 

[Sycostang67]

I got the kit this morning, and I have a fellow IDI owner coming over to lend a hand. Hopefully I can get this done. I found a huge puddle of fuel under the truck yesterday, so it's not going anywhere until this is fixed.

 

[Agnem]

Take a picture of you two working on it! We'd never believe there are 2 people from Idaho with IDI's.

 

[Sycostang67]

Well I got everything replaced. My crossover line was already at the back of the motor, and looked like it was factory setup that way. One cap had already been replaced by a PO but was still leaking and they had also replaced all the hoses on one side of the motor. I dont think I put enough ATF in the filter as I've killed the batteries trying to start it up. Sitting on the charger now, hoping it starts soon as I have an hour drive in morning, and I have to leave at 8.


EDIT: Got it fired up about 3 A.M. and let it run for 30 minutes to check for leaks and charge the batteries. It looks like one cap is still leaking which is better than 4. At least it's an easy one to reach. Should I try fiddling with it, or just get some new rings for that injector and redo it?

 

[k_williams1982]

It looks like one cap is still leaking which is better than 4. At least it's an easy one to reach. Should I try fiddling with it, or just get some new rings for that injector and redo it?

Did you hear it "snap" into place when you put it on? I have tried the getting new o-rings thing, and no parts store in town had the exact size o-ring. I got the closest size I could, and it only lasted about 2 weeks until the caps started leaking again. I have 3 leaking right now (Front 2 injectors on driver's side and the rear one one the passenger side). The truck runs okay still, but it's making a heck of a mess in the GP area (especially when running WMO) and I have to keep it running to purge the air out when I first fire it up in the mornings.

I just got a new return line kit for my truck, but I'm waiting to put in on for two reasons: 1) I'm thinking about pulling my injectors and having them pressure tested and reshimmed, if needed, before I install the new kit; and 2) I'm afraid that I'll still end up with a "leaker" because I've only "half-@$$" fixed my return lines in the past and I don't want to mess up a new kit.

 

[Sycostang67]

Yeah, they all snapped into place. I may check the length of the return lines connected to it, seems if they are too tight it can tweak the way the cap sits on the injector.