Fuel line return kit problem
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Freshman User
Joined: Oct 2010
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Fuel line return kit problem
I am putting a fuel line return kit on and ran into a problem. I have the 7.3 kit and it appears that someone may have put a 6.9 kit on in the past, maybe? Old ones have 3/16" hose on them and barbs look a lot smaller than the new kit's, and I have 1 more fitting than the old setup. Trying to figure out where I should route this extra line. Pic shows the routing it should be and where mine differs from the kit. My options I guess are find a single barb piece, plumb in a T somewhere to put it in the hard line going from the IP to the 2 rear connectors, or cap it off. I am not sure capping would be so good, might pop off?
returnlinekit by jeffreythree1, on Flickr
returnlinekit by jeffreythree1, on Flickr
Methanoholic
Joined: Mar 2009
Posts: 6,442
Likes: 8
From: Maine (NorCal Native)
Yes, you want the layout like the red one was originally ... That is a N/A 7.3 layout.
Loose the hardline down the valley and the cross it goes to at the rear of the motor and replace it with a 1/4"x5/16"x1/4" Tee ... The factory Tee at the back of the N/A 7.3 looks like:
If you haven't already you might read this 94 7.3 turbo idi injection return lines.
There are a couple other good threads on this topic as well.
-Enjoy
fh : )_~
Loose the hardline down the valley and the cross it goes to at the rear of the motor and replace it with a 1/4"x5/16"x1/4" Tee ... The factory Tee at the back of the N/A 7.3 looks like:
If you haven't already you might read this 94 7.3 turbo idi injection return lines.
There are a couple other good threads on this topic as well.
-Enjoy
fh : )_~
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Freshman User
Joined: Oct 2010
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I read that one, its where I got that pic 
. I added the T in the back and removed the hardline from the system. The only issue I have now is what to do with the small fitting that goes into the fuel filter housing, the one with the tiny orifice pinhole in it. It is much smaller than the rest of the new line and fittings. Delete(not sure where air will go afterwards), find a reducer(more clamps, more air chances), or try to find some hose that is close enough to both to clamp tightly on the small end and squeeze onto the larger barb. I have a little time now that I am waiting on injectors and a #6 cylinder fuel pipe after finding one cross threaded and leaking.
. I added the T in the back and removed the hardline from the system. The only issue I have now is what to do with the small fitting that goes into the fuel filter housing, the one with the tiny orifice pinhole in it. It is much smaller than the rest of the new line and fittings. Delete(not sure where air will go afterwards), find a reducer(more clamps, more air chances), or try to find some hose that is close enough to both to clamp tightly on the small end and squeeze onto the larger barb. I have a little time now that I am waiting on injectors and a #6 cylinder fuel pipe after finding one cross threaded and leaking.
Logistics Pro
Joined: Sep 2007
Posts: 3,737
Likes: 179
From: Western Mass
Its possible the "6.9 kit" you mention was original and used the smaller hoses. My 88 7.3 has the smaller 6.9 style return lines. They were most definitely the original ones on mine as the grey paint was still there.
As to solving your problem, a reducer could easily be put in, and I wouldn't worry too much about it causing leaks, I think most of the leaks end up happening at the injector o-rings, not the hose connections.
As to solving your problem, a reducer could easily be put in, and I wouldn't worry too much about it causing leaks, I think most of the leaks end up happening at the injector o-rings, not the hose connections.
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