Elementary Repair

[Jeff Brown]

A couple of the fuel lines on my 91 F250 7.3 idi are leaking at the fitting to the fuel return T's. I'm planning to replace the T's, return lines, and hoses. Is it better to leave the fuel lines connected at the pump while I'm doing this? A Ford service guy told me that sometimes the flare end of the fuel lines crack and the line needs to be replaced. If this is necessary or if removing the lines is necessary will it be necessary to use the special fuel line wrench (OTC 7460 Fuel Line Wrench 5/8 In Hex T83T-9396-A OTC303-230) to remove the lines from the pump?

[cdnsarguy]

Any cheap 5/8" line wrench will do....... line cap nut torque is........22ftlbs

Here is how to....
First disconnect steel injector line cap nuts, "do not bend lines" but move them away individually enough to just 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 several sets 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.

Parts....
( return line kits/ injector install kit )
6.9 Ford Diesel parts Fuel Injection Turbocharger
7.3 L Ford Diesel Fuel Injectors Fuel Pumps Accessories

Air leak and other good info....
Ford diesel 6.9 7.3 IDI

[Jeff Brown]

Thanks for the info and links. I was worried about the $70 socket! I'll get the parts ordered and let you know how it goes.
Jeff

[Jeff Brown]

Thanks again for the instructions. I did the return lines a week or so ago and no more fuel leaks. The plastic caps and lines I got were a bit different than the ones on my engine. They were set up for 1/4 inch lines where the existing ones were 3/16. This was not neccesarily a problem except that a brass fitting on the line that returns to the tank (I believe) has 3/16 fittings for the return lines connected from the line to the back end of the fuel rails. I got 3/16 fuel lines, kept the plastic caps that were existing, and figured that I would save most of the kit for the next time then maybe I'll be able to find one of those brass fittings with 1/4 nipples on it in the mean time. I had no problem getting the engine started.
Maybe the concern about tubing size is unwarrented but I didnt want to do it twice this time. Are the newer, different shaped caps and larger tubing better?

Jeff

[Snotzalot]

You got the wrong return line kit from your supplier. Since you reused the existing caps, you'll be doing the job again, soon. So go find the correct kit.