Plugged Fuel Return Lines or Fuel Selector?
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New User
Joined: Feb 2004
Posts: 3
Likes: 0
From: Yorkville, IL
Plugged Fuel Return Lines or Fuel Selector?
Hello everyone. I have an 87 F350, 6.9 diesel (out of an 85). Started the truck this morning, and after about 3 seconds, it stalled and would not restart. I followed the troubleshooting steps in my Hayes manual, opened the fuel return line at the injector pump and the engine started. The manual says the return lines line are plugged. I came to the forums looking for help on what to do next, and after searching older threads, I'm not sure whether the lines are plugged or the selector valve is bad. What are the next steps I should take? The manual suggested blowing air back through the return line, but I didn't know how to accomplish that. Thanks for the help and fair warning--I am a lousy mechanic 
Senior User
Joined: Apr 2003
Posts: 198
Likes: 1
From: Kansas
If you're a lousy mechanic and keep declaring it, best thing to do is sell the truck!! However, if you're just telling us so we know were to start ( and you're willing to change from being a LM to a M) then keep it and start fixing 'cause if you take it to a professional mechanic every time your truck has an ache it'll nickel and dime you to the poor house.
On top of your injection pump there are 2 elec. connections. One located at froont of IP is ETR solenoid. (energize to run). While cranking engine is must be at least 9 volts.
If that's OK then check voltage an cold idle speed/advance solenoid. (located at left rear of IP) While cranking engine voltage must be at least 9 volts. If no voltage is present, verify switching function of temperature sensing switch located behind thermostat housing.
After you confirm proper voltage is getting to pump, then check for fuel a injector nozzle be loosening nut at injector about 1/2 turn and crank engine to see if fuel is spilling over.
On top of your injection pump there are 2 elec. connections. One located at froont of IP is ETR solenoid. (energize to run). While cranking engine is must be at least 9 volts.
If that's OK then check voltage an cold idle speed/advance solenoid. (located at left rear of IP) While cranking engine voltage must be at least 9 volts. If no voltage is present, verify switching function of temperature sensing switch located behind thermostat housing.
After you confirm proper voltage is getting to pump, then check for fuel a injector nozzle be loosening nut at injector about 1/2 turn and crank engine to see if fuel is spilling over.
Posting Guru
Joined: Oct 2003
Posts: 2,438
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From: Monroe, WA
It's not a plugged return line, you have an air leak in the return line. You most likely need to put a return kit on the injectors. If you arent much of a mechanic you might want to have a shop do it. You can in the mean time, plug the small hose that goes from the top rear of the fuel filter base to the first injector return hose/plastic hat. I've used a small bearing or maybe a BB in the hose and just plugged it back on. Just to check it you can also use a small hose pincher or key nosed vise grip to plug the hose overnight and see how it starts in the morning.
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