return fuel lines
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New User
Joined: Apr 2006
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return fuel lines
How hard is it to chane the o rings and return lines on a 1985 6.9 diesel? I seem to have an air leak somewhere and have blocked off the return line to the filter and water seperator but still have problems starting. I would like to buy a return line kit and replace all the o rings.
Post Fiend
Joined: Nov 2004
Posts: 5,638
Likes: 1
From: Manitoba
Here is how to....
First disconnect injector cap nuts, "do not bend lines" but move them away enough to get the return line caps off as a complete set per side.
After removal of the complete return cap and lines sets, build new sets identical. To remove old orings use a dental or oring pick with a razor knife, do not mark the injector body. When installing orings use lots of grease and roll first one into top groove, then roll second over that to bottom groove. When installing the new lines and caps use grease inside the cap and on orings, place them on respective injectors and gently push straight down until it pops into place on the orings. Install the line capnuts 22ftlbs torque. There should be a small space between the return cap and line capnut when finished, any major leaks mean caps are not seated or orings are cut or line cap nut is not tight. I have done two sets lately and found bleeding 1-2 injectors at a time on opposite side the best. Tighten lines then place fuel pedal to floor and fast idle and timing advance on, crank for 15 seconds max, mine started after 4th injector was on line.
Note when cranking engine and bleeding there will only be a slight amount of fuel/bubbles seen, no major squirting gysers, that only happens with engine running at idle RPM.
http://www.dieselpage.com/dlk.htm for the return line kits
First disconnect injector cap nuts, "do not bend lines" but move them away enough to get the return line caps off as a complete set per side.
After removal of the complete return cap and lines sets, build new sets identical. To remove old orings use a dental or oring pick with a razor knife, do not mark the injector body. When installing orings use lots of grease and roll first one into top groove, then roll second over that to bottom groove. When installing the new lines and caps use grease inside the cap and on orings, place them on respective injectors and gently push straight down until it pops into place on the orings. Install the line capnuts 22ftlbs torque. There should be a small space between the return cap and line capnut when finished, any major leaks mean caps are not seated or orings are cut or line cap nut is not tight. I have done two sets lately and found bleeding 1-2 injectors at a time on opposite side the best. Tighten lines then place fuel pedal to floor and fast idle and timing advance on, crank for 15 seconds max, mine started after 4th injector was on line.
Note when cranking engine and bleeding there will only be a slight amount of fuel/bubbles seen, no major squirting gysers, that only happens with engine running at idle RPM.
http://www.dieselpage.com/dlk.htm for the return line kits
