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FAQ - Diesel - Injector Return Line Replacement Procedure

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Old 02-20-2011, 06:36 PM
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FAQ - Diesel - Injector Return Line Replacement Procedure

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Provided by starmilt
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Steps to change return line
Quote:
#1 Buy a return line kit. You can get by with 16 #11 orings and some fuel line but there is always the chance of cracking on of the T's or one being distorted, so if you don't have any extra ones then buy the kit. (called an injector install kit).

#2 Remove air cleaner.

#3 Lay several layers of newspaper or equivilent on wifes or mothers dining room table.
(this step is the most important)

#4 Clean off all injector line fittings. (you don't want any dirt or grime getting into the open injectors).

#5 Disconect one whole bank of injector line nuts on the injectors. (no need to mess with them at the pump)

#6 Remove the clamps on the ends of that side and pop off the plastic T's one at a time, but leave the whole bank in one piece, one at a time use a little pressure to raise the injector line just enough to remove the T.

#6 Now you can carry the four T's and the hoses still connected into the dining room and lay on the newspaper, this is your pattern. Caution it is best the first time to allow at least 2 hours time before wife or mother is expected to return for this step.

#7 Cut your new hose to the exact lenghts as the old ones one at a time installing the hose and new clamps on the T's when you have all 4 together matching your pattern exactly.

#8 Lube the new orings and carefully install them on the injectors.

#9 Now install back on engine making sure each cap snaps all the way down on the injector. (you have the other side to look at and in a quiet place you should hear/feel the caps snap as they seat)

#10 Reinstall injector line nuts taking care not to crossthread them..

#11 Repeat steps for other side.

#12 Clean up newspaper and remove from house there is always going to be a little diesel smell, so it is best to now go to the bar before wife or mother shows up and take your time telling your buddys all about it. use caution here it is best to go home as soon as bar closes not wait until the next morning they will still mention the diesel smell but you won't mind as much and if you wait longer they will always read something silly into it.
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