What size is the fuel line for the return hoses? I replaced my filter and knocked a couple of hoses off and noticed they are old and cracked to hell. I had some 1/4" fuel hose to patch it but it seems a bit too tight. Should i buy the kit from Pensacola? Are the o-rings that come with it not worth using and get those from McMaster Carr? What other parts should I replace while im in there?

 

Huh, how do you mean?

There are two return line systems out there; the older style had a single barb on each connection, and used 3/16" line. The newer system has multiple barbs on each connection, and uses 1/4" line(the tubes are bigger, too).

Also, tight return line is good; as long as you can get the line on over the connector, you're fine.

O-ring wise, I don't know. It wouldn't surprise me at all if the ones in the kit *were* the same ones as the McMaster Carr ones... It's more that you will end up needing more than one set's worth, if you tweak your system at all.
The O-rings don't seem to do as well these days, what with the ULSD and all, though that may be all a matter of just disturbing them.

Also, a little tip: Use Lithium grease(I'm using wheel-bearing grease) to install your O-rings, not Petroleum Jelly as I've seen suggested. It seems to do very well, and the ones I've installed this way don't 'weep' for the first couple of heat/cool cycles, like they used to.
Also, this lithium grease will not melt at top-of-engine temps; so any that's on the outside of the O-rings will /stay/ there... not that it will make any real difference, I don't think.

 

Cool! More good info for the never-read FAQ.