Return line caps leaking badly
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Tuned
Joined: Jun 2010
Posts: 349
Likes: 33
Return line caps leaking badly
I replaced fuel return lies and caps a few months ago but was still seeing air intrusion. Wiggling the caps would result in fuel leaks, not all, but few. Questioning the quality of the parts in a kit from Pensacola I ordered a new Delphi kit and installed it last weekend. While putting caps on #1 and #8 injectors I didn't hear that distinctive click... and they leak, I mean leak badly. I can see fuel filling up the valley where glow plugs are. #5 and #7 leak too although I heard a click there. Any idea what could be wrong? Did the same on the other truck and no problem there. Ordered Viton o-rings from McMaster and received today so will change them and see what happens. Wish I saved original caps.
And also wonder what are those copper washers which come in the kits for?
And also wonder what are those copper washers which come in the kits for?
Fleet Owner
Joined: Jul 2006
Posts: 20,394
Likes: 852
From: Mi'kma'ki
Make sure to use a lot of petroleum jelly. If you don't feel a good seat. Lift it up, lube it some more and try again. It should have a nice firm seat when correct. I've never had a Delphi kit fail me. The copper washers go under the fuel injectors. If you're changing fuel injectors, they come with the new/reman injectors anyway too, so you'll probably will never use them from an install kit. I've never had a reason to.
Mountain Pass
Joined: Oct 2021
Posts: 222
Likes: 60
I bought injectors and install kit from Pensacola 3 years ago, before learning of their reputation.
(thier website said "To God Be The Glory")
I had expected rebuilt injectors, but recieved new ones and I have no idea of who made them.
Anyway.....the caps in the Pensacola kit were a terrible fit and I reused the old caps.
The OEM caps are a nice tight snap on fit with Viton orings and haven't leaked for 3 years so far.
Best to stay with true OEM quality.
(thier website said "To God Be The Glory")
I had expected rebuilt injectors, but recieved new ones and I have no idea of who made them.
Anyway.....the caps in the Pensacola kit were a terrible fit and I reused the old caps.
The OEM caps are a nice tight snap on fit with Viton orings and haven't leaked for 3 years so far.
Best to stay with true OEM quality.
Logistics Pro
Joined: Jun 2017
Posts: 3,986
Likes: 515
From: Edmond, OK
I've used the Delphi 7135264 injector return line kit before and didn't have any trouble. I've never bought anything from Pensacola though. I use wheel bearing/suspension grease when I lube the top of the injectors.
Trailering
Joined: Jul 2009
Posts: 16
Likes: 1
A lot of the kits are garbage quality. There are a few folks who specialize in our old machines, R&D IDI Performance is one and Classic Diesel Designs is another. If you get your kits from one of them, you're more likely to get adequate quality. Also, there is a fellow on ebay selling machined aluminum injector caps. They're spendy, but they're likely to fit right, forever.
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Tuned
Joined: Jun 2010
Posts: 349
Likes: 33
Viton o-rings solved the problem. Happy to see the engine clean and dry after fixing that and replacing valve cover gaskets. And no more diesel smell under the hood. Hope it stays that way for a while.
Fleet Owner
Joined: Jul 2006
Posts: 20,394
Likes: 852
From: Mi'kma'ki
I just had one leak during my engine swap too. It got late on me and was dark but the next day, I could see the trickle from the cap haha. I have spare caps and o-rings so I just replaced the o-rings and the cap both. I had just installed injectors (last Nov.) on the old engine before it failed, so the caps and lines were all new, so I just re-used them on the replacement engine. It probably just got it dirty, cus I threw them on the floor in a pile. Probably could have just cleaned it and been fine, but I was 4 days replacing an engine, and not about to mess around with it.
Now I'll have to say, I don't normally have Delphi kit's fail me, under normal conditions. That is, when I don't remove them and toss them in parts pile and re-install them.
Now I'll have to say, I don't normally have Delphi kit's fail me, under normal conditions. That is, when I don't remove them and toss them in parts pile and re-install them.
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