i have a 1992 7.3 with 200,000 miles just had work done (valves injectors) only had it back a week so not sure if everything is back to normal. The reason for this work is a long story but my question is the mechanic removed to fuel return line from the front passenger side injector that goes to fuel filter it is capped at both ends.

 

you are going to have to get a pic of that. or show us on another picture of the same engine.

 

it shouldnt be capped off

 

I am ne to these forums not exactly sure how to post pictures but they took off the black braided flex line that goes from the plastic injector fitting back up to the fuel filter

 

well okay now i see which one you mean. As for the need of it, i dont know it is totally required but it can be easily replaced with fuel line. Do you want to just replace it? if so take it back to them and have them explain their reasoning, then tell them to replace it anyway. If they have a good reason, then hear them out but most mechanics dont know squat about our trucks.

 

I was having starting idle issues took it in they did a comprssion test #3 #4 were about 100 lbs lower. cylinder heads were removed and overhauled. They must of still of had problems timing it. removed this return line because it might of been back sucking fuel from filter?

 

I have only been driving it a week but it starts right up in morning and at the end of the work day. there have been two times that it has sat for a hour or so after running fine and whan i went to start it it hard started had to crank awhile. the only issue i have is the idle seems to be a little rough.

 

So you replaced injectors and overhauled the heads? If so how old is the IP?

 

its original. I have a long story so i will try to keep it short and hit the high lights. bought truck from my boss 7 years ago he maintained it very well approx. 150000 on it just got to 200000 no real issues black smoke on hard accelleration or up hill. still original ip and injectors. 2 months ago made long trip to oregon from bay area cali to het a friend out. week later small water leak from pump and passenger side head gasket. had my girlfriend cousin help me (also had a oil drip rear main seal leak) we pulled motor to make it easier to work on replaced pump glo pugs all gaskets and rear main seal. put it back in had trouble starting and getting timing right also black smoke from exhaust. Thought it might be injectors so got new ones still same issues. so thought it was pump or air leakage so took it to mechanic who maintains our company trucks(6 f-250s and one f-450) he had it for 2 months! compression test showed 2 low cylinders had machine shop overhaul and valves he also found timing gear off one tooth. went to pick it up after work completed and told running fine. It wouldnt start. left it for one more day pick it up now stars fine runs good (exept rough idle) thats when they removed return fuel line. wow feel like im writing a book but that gets everyone up to date on my dilema sorry fo epic reply

 

I would like to get idle adjusted but i don't want to take it back to shop. also i have other issues to deal with loose steering and a clunk from front left corner while turning or driving over uneven surfaces. also the oil drip from rear main seal is back. any input would be helpful i have been searching this forum the last couple of days and have been getting alot of good info

 

Loose steering and clunk means something in the steering or suspension are bad. Check the tie rods and ball joints.

 

I agree, even the Ford dealerships don't know squat. The best resource for IDI's is right here on this forum.
Rough idle...do you have a fuel leak anywhere at the injectors or injection pump? My guess is that one injector is leakng and isn't firing because a fuel leak prevents enough line pressure to build up to "pop" the injector open.

Passenger side-


Drivers side - Note that the line running off the back going over to the hard return line at the back of the block should actually be off the T since the second outlet on the T is still capped off. The same with the front line heading up to the fuel filter.


And this is why you can buy "broken, junk, stupid trucks" for $100 when the owner is sick of throwing money at it...


A $40 return line kit will get this going. But this is my engine I plan to rebuild, so it's already out of the truck. This is an 85 or 86 6.9.

I'll get some pictures of the engine in my truck tomorrow, as the returns are set up a little different in my driver.

 

no fuel leaks anywhere. it started right up this morning and it was cold 35 F well cold for california it runs fine it feels like a little more power than i remember. but when i was going approximately 60mph around 2000rpm uphill i felt a "sputter" once then i looked down at tach and felt it again and saw in on the needle small drop. then the rest of the day it was fine. I was trying to make it happen again same speed and different situations. For right now just glad it starts ok and runs. But if i can find some useful info to how to correct idle without messing up anything i will be patient. For some reason I am wodering about fuel delivery from tank to filter. Could air get in from there because as of now the engine top end has been redone exept fuel pump and this return line to filter. as for the left front clunk i jacked it up today and looked around nothing out of the ordinary no up and down wheel play a little side to side at pitman arm but i am not sure that is normal or not. also i not sure if that could be the loud clunk popping noise i'm hearing. maybe spings? I replaced steering tie rods and sway bar bushings last year. Iappriciate all the input and I will keep tring to figure this out.

 

why do you want the idle adjusted is it too low?

 

That short line that goes to the return lines is a bleed line...It lets excess fuel back into the return line and it helps bleed air off the system...Doesn't have to be there but I wouldn't want it gone. Any air you get that gets into your fuel filter when you change the filter has no choice but to go through the injection pump. They don't like air. I took it off my 83 one time because I needed to replace it. Anyway it was awhile before I got to it and I noticed a big difference in how the motor first ran after I changed the fuel filter.