It's crazy how these trucks can sit and then when called upon, fire right up like you ran it yesterday. It fired immediately, but then died... Return line air intrusion. After two cranks, it was alive. I popped the hood and discovered all of the cloth braided hoses had pinhole leaks in them such that fuel was misting out. I replaced all of it with legit low pressure fuel line, not the cloth braided crap.

I haven't had o-ring leaks since I replaced the return line caps with the brass ones in mid-to-late 2010, but decided to replace the o-rings anyway since I needed to remove the system to replace the hoses. Which leads me to the next discovery of the day... Silicone Spray. By far, the best lubricant I've used thus far to replace the o-rings and I've replaced them A LOT when I struggled with constant leaks before the cap swap. I sprayed the injectors and the o-rings went on like butter. I was so impressed, I sprayed the installed o-ring laden injectors and the inside of my brass cap assembly. The caps went on just like the old style plastic ones with a definitive snap/click into place. That was the first time that happened. I highly recommend the silicone spray for this job.

I hoed out the truck and it's ready for detailing. I think it's time to let the truck go to the next owner who will get more use out of it than I do. I'm going to take a major bath by selling it, but I don't really need it anymore. I can't believe how much work I put into the truck to make it what it is today. Oh well... If it was a CCLB, it would be a different story, but it's not.

If you haven't done so yet, get rid of that junk cloth braided line and install some low pressure diesel rated fuel line. For the 6.9L, NAPA carries Gates GL031525 D2 - 3/16" ID | 3/8" OD fuel line. I believe it was $1.64/LF. You'll need 5' minimum. McMaster-Carr has the best price on o-rings, #111. Give the silicone spray a try - WalMart carries it on the cheap for ~$3.00/can.

 

Where did u come up with brass caps for the injectors

 

Built them.

 

Nice wish I had a set of them wouldn't have to worry about breaking them

 

I've been using wheel bearing(lithium) grease for my caps; it seems to work just the same way. Tons less problems with leaks since I've begun using it.

 

i've got a set of the brass caps and i love them

 

Wander how much it would cost me to have a set made

 

I can't PM you for some reason.

 

Nice! They install OK for you? Try that silicone spray... Like butter.

 

because he is a new user and has not been here long enough to get PM privileges yet.