Napa calls them injector instalion kits if your lines are popping off that is something I have not run across.
Are you running an electric pump.
Return line obstructed maybe.

 

ok, this might be a stupid question, but do you have to remove the turbo to install the return line kit? and if so, whats the best way of doing it?

 

Ya I'm running a electric pump as well it was in line when I got the truck. And the line from the back of the passengers side does not connect to the back of the drivers side its just plugged off and that's where the return line is so maybe that is part of my problem I haven't seen it any other way tho anyone have any pics?

 

From the IP the return line runs to the drivers side front injector. The pass. side injectors are all T'ed with each other and the rear one just feeds forward (not to the drivers side). I think the second injector back on the pass. side there is a cross line that goes to the drivers side second injector back. Only the driver side rear injector should be feeding the return line to the tank.

Hope that makes sense. lol A pic would be easier to follow.

 

Yes they can be changed without removing the turbo.

 

Do not remove turbo. Even your first time you can replace your return lines in 2 hrs.
Do a search on here everything has been explained several times if you have any questions just ask.
Is your T plugged on the injector itself It has to be connected to the block going to the tank.
You said electric pump as well have you got both hooked up if so you run the chance of filling the oil pan with diesel if your manual pump diaphram goes.

 

On turbo engines, the return line usually starts at the rear passenger side injector and runs to the front picking up each injector.

Usually the second from the front injector has a triple tee that connects to the third from front and front injector, plus a cross over line to the drivers side second injector.

The front injector on the passenger side has a doube tee, that connects to the second injector and the fuel filter return line.

The front injector on the drivers side has a double tee that connects to the second injector and the IP return line.

From the second injector drivers side, the return line runs to the back injector, which then continues to the return line to the tank.

Clear as mud, but I hope you can make sense of what I said.

The bad thing, I have seen about three different setups for both NA and turbo engines.

In the end, the important thing is each injector, plus the IP and the fuel filter are all tied into the return line.
I need to take a picture of return lines.

 

No picture hard to belive.

 

ok, i got my return line kit in. where do the copper washers go? also, i will be taking my injectors out to have them pop tested. any info i need to know before doing that?

 

The copper washers go under the injectors.

Make sure you get the old ones out before putting the new ones in.
I think some guys put some grease on them to hold the washer on the injector for reinstalation.
Since I'd use anti-sieze on the threads anyway I'd just use that sparingly instead.
Personally I'd try to keep the injector nozzle as clean as possible.

 

ok, so i pull the injectors out and place 1 copper washer on the bottom of each injector and place them back in?

 

Yes and be very careful of the little pintle sticking out of the end of the injector nozzle.

As Dodge said, when you remove the injectors, make sure the old washer comes out with the injector.
If it does not come out with the injector, pull it out before you remove the next one so it does not get left in there and another one on top by mistake.

 

ok, i had my injectors pop tested and 3 of them are bad... where is the cheapest place to pick up 3 injectors? are the injectors for the turbocharged motor different from the non-turbocharged motor?

 

Yes they are, I would get them from MWFI.
However there are lots of places that sell them.
If I remember right they are G code injectors for the turbo.

 

i think mine are going out i need to ready to change them