new fuel return lines?
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New User
Joined: Jun 2006
Posts: 7
Likes: 0
new fuel return lines?
I have an '85 6.9 liter diesel and I have been having trouble
getting it to start and run well... when I bought the truck it ran ok,
but since I had to fix some leaks in the fuel return lines it has developed
some problems starting... after chasing up the wrong tree a few times
(thinking I had conquered the fuel line problem), I'm back to thinking that
it's just a problem of air leaking into the return line near the filter.
I have already done as another user who posted a similar thread on returns,
in fixing the return line which used to T between the front injectors on the
left side... now it's a straight line from the front injector up to the filter...
but I'm not sure what I've used to make the new line is working well. so
what I'd like to know, is what kind of replacement lines I should be using...
previously, I used some synthetic rubber 3/8 line and some hose clamps, probably this is where I went wrong... the clamps get so tight then they bite
into the rubber and they won't go any tighter... is there some kind of a kit available, with fittings that would connect more tightly than my hose clamps?
what is the best solution to this dilemna? thanks, still have much to learn...
getting it to start and run well... when I bought the truck it ran ok,
but since I had to fix some leaks in the fuel return lines it has developed
some problems starting... after chasing up the wrong tree a few times
(thinking I had conquered the fuel line problem), I'm back to thinking that
it's just a problem of air leaking into the return line near the filter.
I have already done as another user who posted a similar thread on returns,
in fixing the return line which used to T between the front injectors on the
left side... now it's a straight line from the front injector up to the filter...
but I'm not sure what I've used to make the new line is working well. so
what I'd like to know, is what kind of replacement lines I should be using...
previously, I used some synthetic rubber 3/8 line and some hose clamps, probably this is where I went wrong... the clamps get so tight then they bite
into the rubber and they won't go any tighter... is there some kind of a kit available, with fittings that would connect more tightly than my hose clamps?
what is the best solution to this dilemna? thanks, still have much to learn...
Post Fiend
Joined: Nov 2003
Posts: 21,285
Likes: 16
From: Nutter Fort, WV
68dutchguy,
The problem is probably the O rings under the return tees.
The hot fuel makes them hard, they do not like to be disturbed once they are hard.
Fuel resistant tubing is great for making the lines, should be a stock item at any parts house.
The O rings are either a fuel injection service or a dealer item.
It takes 16 O rings, I would get a spare or two.
They are easy to drop, when that happens they usually go to parts heaven.
Never find them again unless you are in a shop with a very clean floor and have great eyes.
They are also easy to break as you install them.
The problem is probably the O rings under the return tees.
The hot fuel makes them hard, they do not like to be disturbed once they are hard.
Fuel resistant tubing is great for making the lines, should be a stock item at any parts house.
The O rings are either a fuel injection service or a dealer item.
It takes 16 O rings, I would get a spare or two.
They are easy to drop, when that happens they usually go to parts heaven.
Never find them again unless you are in a shop with a very clean floor and have great eyes.
They are also easy to break as you install them.
Elder User
Joined: Oct 2006
Posts: 597
Likes: 0
Don't know if you're using them, but those "worm drive" clamps don't work too well for return lines because they aren't round enough when trying to clamp such a small hose.
When I first got my 7.3 and had leaks, I got a "return line kit" (from Autozone, $30 - $35 if I remember right). But then I thought "those little spring clamps aren't any good, I'll use better clamps...". There were leaks everywhere. Then I went back to the clamps in the kit, and haven't had any trouble since.
When I first got my 7.3 and had leaks, I got a "return line kit" (from Autozone, $30 - $35 if I remember right). But then I thought "those little spring clamps aren't any good, I'll use better clamps...". There were leaks everywhere. Then I went back to the clamps in the kit, and haven't had any trouble since.
