Return Line Grief Suggestions

[OldIron82]

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Ok so far everything has been going as expected but right at the end... One snag. This "manifold" that the return lines go into at the back before they go down the main line to the tank. The two chicken **** tiny nipples are way to thin for the new return line hose to fit on to. They just fall into it and even a hose clamp won't tighten it. It just crushes into a oval. Any suggestions? Thanks.

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[Clb]

Unfortunatley
There are 2 size line sets.
Try a short section of the ?1/4" and a 1/4-3/16 union pipe.

 

[franklin2]

I would get new rubber lines that fit better. If you really want to use the setup you have, a small wire tie would probably take up the slack without crushing the barb fitting. But I think new line is your best bet. Napa sells that small line, you can't use vacuum hose or washer hose, it needs to say "fuel" on it. When I replaced my o-rings and lines, they had the proper line in stock. I didn't buy a "kit". They probably have the o-rings in stock also.

 

[crash-harris]

Connect the IP return to injector #2 (closet to grill on driver's side) and use that plastic tee in place of the manifold. I just today connected a brass tee with two 1/4" nipple and one 5/16" nipple in place of my return manifold.

 

[typ4]

And here is a perfect example of why I always ask folks which style kit they need.
Early, 5mm usually with green clamps and centered nipples on caps.

Or late,7mm usually with red clamps and offset to one side nipples on caps.

 

[Clb]

^^^^ exactley why we have a hall of shame! Guys just selling parts.
Ta da!
Then there is the non turbo truck with a turbo.
Reading the stickies ......
But I'm getting hammered so I may be off base.

 

[OldIron82]

Wait, wait, wait, hold on. This IS a kit for a turbo engine. I was asked and I responded naturally aspirated but I am putting on a first gen Banks turbo, so this is the kit I was sold under the pretense it would be going on a turbo engine. My bad

@ crash-harris: So it is ok to eliminate the long pipe that runs the entire length of the intake manifold that drains the injection pump?
@Clb: I think I'll try the 1/4-3/16 union.

I'll sleep on it. Thank you once again gentlemen.

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[Clb]

The rerouting of returns can go any way you wish ( given it goes back to tank) my non gated banks rocked! Talk to type4, he is busy but the man for reworking up this stuff, mel also.
Linkage issues, auto or manual are the big issues.

 

[crash-harris]

Wait, wait, wait, hold on. This IS a kit for a turbo engine. I was asked and I responded naturally aspirated but I am putting on a first gen Banks turbo, so this is the kit I was sold under the pretense it would be going on a turbo engine. My bad

@ crash-harris: So it is ok to eliminate the long pipe that runs the entire length of the intake manifold that drains the injection pump?
@Clb: I think I'll try the 1/4-3/16 union.

I'll sleep on it. Thank you once again gentlemen.

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Yup. You can use a brass or plastic 4 way and run rewritten line hose there instead of the manifold, or route your return lines like this, or like Mel's preferred method.

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[icanfixall]

Yup. You can use a brass or plastic 4 way and run rewritten line hose there instead of the manifold, or route your return lines like this, or like Mel's preferred method.

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This is a very good pic of how its done. No matter what. You can't run both large and small return lines on the same engine. you end up with issues like you have. Now you CAN change back to the green smaller lines and everything will be fine. Even if you have a turbo on the non turbo engine. Any fitting you use for the problem area you posted about will work fine. But remember you still have other smaller fitting. One is the filter bleeder and the other is the large return line that is steel running from the return off the injection pump. You really do not need that hard line returning off the pump. A piece of any size return line can be used in place of the hard line. Just don't get caught up in an particular run direction. Just make sure everything runs to the back number 8 injector where you had the header manifold.

 

[no mufflers]

I used the smaller line with the green clamps, I think there for the 6.9. I think they look better and are neater in design.