I have a 1994 7.3 turbo diesel IDI and I noticed that the top of the fuel injectors had diesel on them. Is there a seal in the injector rail that I need to replace and does anyone know how to do it?

 

When you remove the fuel injection off of the fuel nozzle the umbrella will come off of the nozzle. There are two o-rings on the nozzle. They aren't expensive, either is the 3/16 fuel line. It is an easy repair. You might want to go ahead and replace the umbrellas also, they can crack.

 

thank you very much for the info

 

Replace all of the return line O rings, or you will be chasing a leak forever. You can get a kit from diesel injection service for around $ 28 + shipping, the kit comes with the O rings, top hats, fuel line and clamps. Remove all the injector lines on the bank you are going to work on,try to "spring" them out of the way to get the top hats off. Remove the O rings, replace the top one first, then the lower, Make up the top hat return line from the old one on the bench. You will have to buy 2 or 3 top hats from ford, if I remember they are a 3 way. Hope this helps Almost forgot, disconnect batts and unbolt the GP controller, this will give you better access to the rear injector returns.

 

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.


Get parts at.......ensure they are for Ford.

http://www.mwfi.com/Dieselpage.htm
http://www.dieselpage.com/

 

could this possibly happen at the injection pump as well?

 

The return lines are the most common point of air intrusion on all the IDI engines.

The other common point for air intrusion is the filter return line check valve.

The 86 and earlier trucks also had a water seperator mounted on the firewall that would leak air into the fuel system.

If it is happening at the IP, the IP is bad.