Fuel line return leaks 1992 ID Banks TurboI need it running by Friday night (Saturday morning trip)

Richard Clasby

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Here are a few pictures. Thank you.

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Richard Clasby

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Sorry I put captions on the picture files and I thought they would show here. Not!
The first 2 pics are the fuel line to #7. It's encapsulated in a plastic shroud and runs under the turbo housing. The line is crumbling.
The last picture is from #8 under the turbo intake to behind the engine.
 

Richard Clasby

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Clb
think I saw a sticky that showed the lines connected to the injectors but it did not show the connection to the fuel tank. Please direct me to that sticky. Thank you.
 

Richard Clasby

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It looks like I need to somehow get to that T fitting behind the engine. I can't even see it. I'm not a pro...Is pulling the Turbo even an option? I'll take it to a local mechanic if that's last resort.
 

Richard Clasby

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Clb
Sorry Now I see it...boy that's easy to see with out the turbo. Well now that I know what I'm looking for I'll go and wrestle with it. You've been a big help. I'm sorry I had to ask, but I seem to be unable to search the old posts properly. I guess I'm just new. But I love this truck so I'll be here for a while. Thank you again.
 

Clb

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I cannot get into my subscribed threads ....
There is a "how to reroute the returns for turbo install" or something like it.
Anyhow
Literally, all ya need is to have a return from both rails back to the tank...
Route em both over to the t gizmo on the drivers side rear head\intake tree(if it exists) seein how it looks like an p.o. has fabbed up some ****

Also look at the return line stickie...
That may have the routing in there.
 

Richard Clasby

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Thanks...Yeah. I'm probably going to need to reroute them. I can't get to the T fitting (or even see it) If I can reroute it to the fuel line under the truck that should work.
 

gandalf

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If you have that T fitting, and re-route to join the return line under the truck somewhere, you probably do not want to leave an open port on that fitting. That wouldn't work too well.
 

icanfixall

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tHANKS FOR THE GOOD CLEAR PICS. tHOSE "LINES" ARE NOT WHAT YOU THINK. THEY ARE YOUR THROTTLE CABLE AND THE CRUISE CONTROL CABLE. i DO NOT SEE ANY RETURN LINE FUEL LINES RUNNING UNDER THE TURBO. bEST WAY i CAN EXPLAIN THE RETURN LINES IS ALL YOU NEED IS THE FUEL TO GET BACK TO THE FUEL TANK. sO DO THIS. rUN EACH SIDE OF THE INJECTOR RETURNS ANY WAY YOU CAN BUT GET THEM TO FLOW BACK TO THE MANIFOLD UNDER THE NUMBER 8 INJECTOR. oN MY ENGINE i INSTALLED A tee BETWEEN THE NUMBER 1 AND 3 INJECTOR. i RUN MY FILTER AIR BLEED TO THIS LOCATION. THEN YOU MAY RUN THE PASSENGER SIDE RETURNS OFF THE NUMBER 1 INJECTOR OVER TO THE NUMBER 2 OR 4 INJECTOR RETURN ANY WAY YOU WANT. YOU CAN USE THE CAPS OR USE A tee. sOMETIMES YOU MAY NEED TO PLUG A CAP RETURN BARB TOO. fOR THAT i FILL THE BARB WITH rtv. rEMEMBER THERE IS NO PRRSSURE ON THIS RETURN.. tHERE ARE SOME VERY GOOD RETURN PATH PICS ON THIS FORUM SOMEWHERE TOO. mEL POSTED THEM. i ACTUALLY LEARNED THE tee INSTALL FROM HIM YEARS AGO TOO. fINALLY ON THE EARLY RETURN SYSTEM WITH THE SMALLER LINES. uSUALLY THIS SYSTEM HAS THE METAL PIPE RUNNING DOWN THE DRIVERS SIDE OF THE INTAKE MANIFLD AND WAY BACK UNDER NUMBER 8 INJECTOR IS THE INFAMOUS THREE WAY FITTING ON THE END OF THIS PIPE. iT HAS AN OLIVE IN IT TOO. THEY DO LEAK AND CAN BE TIGHTENED. bUT REPLACING THEM IS A GOOD IDEA. aGAIN THEY ARE NEARLY IMPOSSIBLE TO DEAL WITH BEING UNDER THE HARD INJECTION LINES AND BOLTED FRONT AND BACLK TO THE INJEKE MANIFOLD. IF YOU DECIDE TO REMOVE AND JUNK IT JUST CUT IT OUT BUT BE SURE YOU HAVE THE NEW MANIFOLD TO BOLT INTO THE REAR LOCATION FIRST. BTW sorry for the yelling. Fat fingers hit the caps key and I have the sound turned off so I get no blip warning tone...
 

IDIBRONCO

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Sorry, but you are wrong icanfixall. The second picture clearly shows the two cable, the wiring harness and the return line all running underneath the turbo. In fact, I can see that the return line is frayed at the #7 injector and also that the very outer layer of rubber is flaking off of the outside of the line. The return line is wrapped in the flexible plastic that looks like wire loom covering.
 

snicklas

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Take a look at this:

http://www.conestogadiesel.com/support/fuellineroutingoptionsforfordidiengines.html

This is from Conestoga Diesel (Mel). Use the top diagram, and that will work. Ignore the one going under the turbo........

The main point is, as long as all 8 injectors, the IP and filter are all connected to the return line to the tank on the drivers side rear of the engine. The return line in the split loom conduit is some PO home brew. You are getting too hung up on that line under the turbo. The main part you need to be concerned with is getting the lines to the TEE on the drivers rear...... Forget/abandon that line and run all new. The configuration of the lines is not important, as long as all 8, IP and Filter have a path to the tank......

Heck, you could start at #7 under the turbo with a dead end cap, connect them 7,5,3,1, across the front and tee in the IP and Filter, up by the IP, the down 2,4,6,8 off to tank....... That would be the most complicated, but it would work.... For a turbo application, I would use the top diagram on the above page, you would be good to go, and have to interact the least under the turbo/air box.....

For ease of use, and for future searches, here is the diagram I am talking about: (Thanks Mel)

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icanfixall

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Thanks.. I now see the return fuel line wrapped in the electrical wire harness wrap. Getting to the rear drivers side manifold in the return line system is ruff but you should not need to remove the turbo. On mine I removed the two intake manifold bolts to get the manifold clear to work on it. If you find the bolts hit the bottom of the turbo housing just know they can be wiggled out. Once out grind off two threads so they install easier.
 
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