Return line rail

steeldriver

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i have been curious on these fuel return lines and seriously considering it. i have spent $240 in new caps and o rings in the last year. most i have gotten a refund or exchanged on some. i have tried stock and over sized o rings to seal. stock work best but give it 5 to 10k miles and its leaking and not a small amount either. loosing 3 to 4 gallons on a 20 gallon tank. fix it and back at it again. injectors are new. old injectors had the same problem. i have worked on idis if it has original caps and o rings just replace the o rings or else they will leak and be a constant problem. i oil the orings before installing which helps. bigest problems is the quality of plastic on new caps. they do not handle well with cold wetaher. srping and fall is the worse for leaks as temperatures are changing. i got 3 new leaks that will have to be addressed. i have put over 100k miles on this in the last year.

if these metal solid lines work i would be interested. anything is better then these caps and o rings.
 

Thatoneguy

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Gotta say I'm in the same boat with some others on the expansion. If you really break it down...

The linear thermal expansion coefficient is the ratio change inlength per degree temperature to length.

The average of the different series' of Aluminum alloys for temperature range where thermal expansion is a factor is 68*-572*F.
Within that range you are looking at a 13.2 linear thermal expansion at 10^-6.

On a material that is a Grey Cast alloy such as this the average temperature range for thermal expansion is 32*-212*F.
Within that range you are looking at a 5.8 linear thermal expansion also at 10^-6".

The determining factor that I see is going to be the O-Rings. I don't have a clue what a "Viton" O-ring is or any other kinds of o-rings for that matter. I just know what an o-ring is lol.

I'm thinking that even if the o-rings are able to withstand, in my mind I don't see it being a long-term solution. I see it as a prolonging a common failure. Which is still better than stock so if I'm right then it would be worth it!

Sorry for the complete nerd rant there. Just my .02
 

Thewespaul

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i have been curious on these fuel return lines and seriously considering it. i have spent $240 in new caps and o rings in the last year. most i have gotten a refund or exchanged on some. i have tried stock and over sized o rings to seal. stock work best but give it 5 to 10k miles and its leaking and not a small amount either. loosing 3 to 4 gallons on a 20 gallon tank. fix it and back at it again. injectors are new. old injectors had the same problem. i have worked on idis if it has original caps and o rings just replace the o rings or else they will leak and be a constant problem. i oil the orings before installing which helps. bigest problems is the quality of plastic on new caps. they do not handle well with cold wetaher. srping and fall is the worse for leaks as temperatures are changing. i got 3 new leaks that will have to be addressed. i have put over 100k miles on this in the last year.

if these metal solid lines work i would be interested. anything is better then these caps and o rings.
Make sure you de-burr the caps of any sharp edges before installation. Mine have lasted 100k with one change of the o rings
 

Macrobb

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Just use high temp grease. I use the cheapest caps possible just to prove a point - it does not matter. Use viton O-rings, grease them up and call it good.
 

IDIoit

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Just use high temp grease. I use the cheapest caps possible just to prove a point - it does not matter. Use viton O-rings, grease them up and call it good.
I used the cheap caps once. casting flash all up in the ID, but after some file work, it sealed
 

Hydro-idi

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I've always used return line kits from Russ. Hell, I've even reused the caps & changed out the viton o-rings and never had a leak. Good quality kits won't leak & should last at least a decade
 

pelky350

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I've only changes caps once in 5 years, o rings only got changed because I put new injectors in but I re used caps and lines and so far no leak for 2 years, caps were on 3 years before changing o rings
 

IDIoit

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little update.
the rails have been holding well after a few heat cycles,
but I did try to get to my valve covers and decided to modify the rails.
now I can get to the bolts again.

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Thewespaul

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little update.
the rails have been holding well after a few heat cycles,
but I did try to get to my valve covers and decided to modify the rails.
now I can get to the bolts again.

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Did you end up plugging any of the ports on the rails? There’s a few places on mine there was no way a hose was attaching there
 

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