Return Lines
Elder User
Joined: Aug 2007
Posts: 728
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standard fuel line works fine , there are two different sizes depending on year model it could be 3/16 or 1/4 inch
if i remember correctly if the factory spring clamps are green it is 1/4 inch
red clamps are 3/16 line
also reuse the spring clamps they work much better than small worm clamps like used on automative fuel lines , the worm clamps can bunch the hose where the wide part of teh clamp is an cause an air leak teh spring clamps have 360 degrees of clamping pressure
if i remember correctly if the factory spring clamps are green it is 1/4 inch
red clamps are 3/16 line
also reuse the spring clamps they work much better than small worm clamps like used on automative fuel lines , the worm clamps can bunch the hose where the wide part of teh clamp is an cause an air leak teh spring clamps have 360 degrees of clamping pressure
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New User
Joined: Feb 2006
Posts: 18
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cool thanks for the info im also gona look at the black plastic things that the return lins run throug becous i think there is a leak at one of them i tried to tightn the line but it was tight ...not unless there are o rings in there some where
Post Fiend
Joined: Nov 2003
Posts: 21,285
Likes: 16
From: Nutter Fort, WV
There are two O rings under each cap.
The hot fuel returning through the caps makes the O rings hard.
If they are moved after the rubber gets hard, they don't reseal and you have an air intrusion problem.
The hot fuel returning through the caps makes the O rings hard.
If they are moved after the rubber gets hard, they don't reseal and you have an air intrusion problem.
Senior User
Joined: Nov 2003
Posts: 156
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From: denver
I've been using a blue 1/4" urethane line from Parts Unlimited. So far it has worked great. It is clear as well so you can see if you have air bubbles. It is only rated to 220 degrees, so keep it off hot stuff. You will need new clamps for it as well. Here is a link to the catalog page: Parts Unlimited | Offroad Catalog
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New User
Joined: Feb 2006
Posts: 18
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i went and bought a return kit today for $60.00 so ill do it this weekend at the same time ill check my glow plugs if i need to replce them i think ill go with the delphi brand .thats what the desil mechanics told me .any how in put is welcome on the gp.also how do i bleed the system after i replace the returns and caps
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Joined: Nov 2003
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From: denver
If you do a search on glow plugs in this forum, you will find lots of info and stories of broken off glowplugs. Most everyone says motorcraft zd-9's are the best. To bleed air out, just crack open the injector line nuts at the injector and crank the engine until bubbles just start coming out. Don't crank it more than 20 seconds at a time and let the starter cool off or you will burn out the expensive starter.
