GP removal help...

[timothyr]

86, 6.9 NA ...so I have all replaced but 2, the ones directly under the fuel line supports. I do not have a tool to get in there (offset wrenches are not offset enough, deep sockets to tall etc.). Is there a reson not to remove the fuel lines, and if not what kind of issues am I going to run into when I put it all back together.

[rupejosh]

if im thinkin correctly i just popped the fuel line keepers off and slid a 1/4" extension between the fuel lines

[Dave Sponaugle]

And after the glow plug is loose, a short 6" piece of 1/4" fuel line will turn the glow plug and pull it out.

Same trick puts the new one back in the hole.

[timothyr]

was able to get in and do the left bank no problem using the fuel line trick, but can't seem to get anything in on the right (passanger)...if I had another 1/4" of wiggle room I'd be done.

If I pop the lines what other mess am I going to open up?

[Dave Sponaugle]

Possibly the return lines.

Just try very hard to not disturb them, loosen the line in the way and move it as little as possible.

Be careful as you start to loosen the injection line nut, make sure it turns on the injection line so you don't crimp the line.
They get a little stuck sometimes, so if you are not watching you can damage the injection line, which cost close to 50 dollars each.

[timothyr]

Dave, this brings me to another thought....just on the right side there is a little fuel in 2 of the glow plug wells....the injectors, and the piece that the return line connects to look new, but the lines were clearly not replaced at the same time.

when mentioning age, I am using grime as the judge...the injector assemblies are prestine, the braided cable going up to it is filthy and tattered (along with the rest of the enigine compartment)

[Dave Sponaugle]

Sounds like return lines and O rings will be your next project.

How is the engine starting after it sits for a while?

Start then stumble or stop after about 15 seconds running indicates air in the filter.

[timothyr]

other than the gp issue she is running fine...I deffinatly am going to replace the return lines in the next week; they almost look original. Do you have an exploded view of the injeector and return line assy. from what I can tell, it looks like there is a return fitting that screws into the injector itself. If that is the case, the po replaced everything except the rubber lines that runs between them

[fatkid89704]

i just did my glow plugs and the easiest way i found t get the two center ones out was to use 1/4" drive with a deep socket and a universal joint just above the deep socket.and putting them back in with the fuel line is the easiest way to go.be sure to test all your glow plugs and keep the good ones just in case you need one in the future.

[timothyr]

what is the easiest way to test them outside the truck?

[fatkid89704]

use a volt ohm meter and check the ohm resistance of the plug.touch one lead to the threads and the other to the wire connector on the end.it should be between 0.5 and 1.0 ohms.any higher then that and the plug is bad.hope this helps.

[timothyr]

thanks....it does

[Dave Sponaugle]

The return line caps on the injectors have two O rings under each of them.

There are grooves in the top of the injector where the O rings are installed.
Inside the caps, there are very slight depressions that the O rings kinda snap into when you reinstall the caps.



Starting at the far right, the threads for the injection line nuts.
Just to the left of that, first O ring groove.
Then the raised part with the bleed hole drilled in it.
Then the second O ring groove.

Use care not to scratch or damage the injector when you remove the old O rings.
Oil the O rings before you install them.
Install the top O ring first, then the bottom one.
Just roll the bottom one across the top O ring till it gets to the bottom groove.

Oil the inside of the return tees before you install them, press down firmly but watch the line nipples.
You will feel a slight snap when they seat.

Some people build the return lines and then install the whole side, others build them on the engine.

I have done it both ways, about the same to me either way.

[timothyr]

thanks dave...that is exactly what I was looking for; and this project is now on...2 cracked return lines and now leaking fuel all over....but hey, the glow plug system works

still wouldnt trade my idi for anything