Ford 83-94 6.9 and 7.3L General Discussion of 83-94 6.9 and 7.3 Liter Ford Diesels

How do I replace return lines?

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Old Jun 30, 2010 | 03:14 PM
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Question How do I replace return lines?

This guy that wants my truck has to sell the one he has first so I figure I got time to do some work on the truck since I still have to drive it for the time being. So how do I replace the injector return lines?
 
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Old Jun 30, 2010 | 04:59 PM
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so one side at a time, loosen and lift outa the way gently the injector lines. now pull up on the plastic caps. they will pop off. replace orings and caps, then cut the line to fit.

put a little oil on the orings before installation so the caps go on better.
 
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Old Jun 30, 2010 | 05:53 PM
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I watched a video that kind of showed what I need to do but the guy took the injectors out, do I need to do that?
 
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Old Jun 30, 2010 | 08:42 PM
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u can, the kit shoudl include new copper washers for the bottom of the injector. but my thinking is if they aint leaking, dont touch em.
 
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Old Jun 30, 2010 | 09:39 PM
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And how would I know if the injectors are leaking and if I would need to replace that washer?
 

Last edited by FordDZLMan9191; Jun 30, 2010 at 09:46 PM.
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Old Jul 1, 2010 | 12:18 AM
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It's hard to tell sometimes. You can spray some soapy water around the injectors with the engine running and watch for bubbles. I had 2 that were leaking, the compression forced soot into the gap between the injector and block and I needed a slide hammer to remove them.
 
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Old Jul 1, 2010 | 09:04 PM
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Ok, maybe I'll try that tomorrow when I tackle the return lines.

---AutoMerged DoublePost---

I got the new return lines on and everything is tight but I still have 2 leaks. The injector on the front passenger side and the one on the back driver side. Any ideas? Bad injectors?
 

Last edited by FordDZLMan9191; Jul 1, 2010 at 09:04 PM. Reason: Automerged Doublepost
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Old Jul 1, 2010 | 10:32 PM
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possibly tore the orings when installing the caps. i did this the first time i did mine, long time ago.
 
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Old Jul 3, 2010 | 01:06 AM
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Make sure the plastic T's snapped down all the way.
 
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Old Jul 3, 2010 | 01:48 AM
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I checked that they snapped down multiple times. I'll try to check to see if I tore the orings. If its neither of those what else could it be? The injector lines are tight and not leaking from there.
 
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