Please excuse my ignorance...new to diesel engines and this forum. I need help please! While changing the air filter on my 1988 Ford F250 7.3, I noticed fluid on the top of the engine in the area of #1 GP. The fluid was diesel fuel. I wiped it clean and monitored the engine as it was running for about thirty minutes in order to search for the leak. I discovered that the #1 injector was leaking. Upon closer inspection, I also discovered that the #3, #4, and #5 injectors appeared to be leaking as well, although the #1 injector was much worse. I called my buddy who I purchased the truck from and he advised that my injectors probably needed cleaning or replacing. He suggested that I make sure each of the injectors and hard fuel lines were tight and to put some diesel fuel injector cleaner in the fuel tank. I asked about torque specifications for the injectors and hard fuel line nuts and he advised, "Just make sure their tight, but don't crank on them". Well, I added the fuel injector cleaner and checked and tightened all of the injectors and hard fuel line nuts. I drove the truck for two short trips (less than fifteen miles) over the next two days, then inspected the fuel injectors once again. Now, I've discovered that ALL of my injectors appear to be leaking, some worse than others. I'm guessing that I have over torqued the injectors and/or hard fuel line nuts. The truck will start, with some degree of difficulty, and runs okay once it does start. But, I've obviously created a bigger problem and don't want to go back to my buddy for his advise. Can anyone offer some guidance on where to go from here? I'm assuming that I'll need to replace all of the fuel injectors - which Autozone has listed at $49.99 a piece. Will I need to replace any other parts? Any suggestions as to where I may find quality replacement parts cheaper. Thanks in advance for your help.
Hold off on the injectors for now. On each injector, there is a plastic cap with two o-rings beneath the cap. You need to buy an injector install kit. It costs $30. and you can get them at: www.dieselpage.com/dlk.htm The kit comes with all the o-rings, caps, cut to fit hose with clamps and copper washers that seal the injector to the head. The injectors get torqued to 35 ft/lb, and the hard fuel lines are torqued to 22 ft/lb. If you end up needing to replace the injectors, they are available for much less than $50 each. Try the injector install kit first, then go from there. Tim
Okay, thank you Tim. First diesel I've owned and still learning the ropes. If I have further questions or run into problems, may I contact you once again for guidance?
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.
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93 F250 7.3 IDI S/C XLT 4X4 E40D 3.55LS, Captains chairs, Tutone Mocha, Leer 48" Hiboy cap, FR & RR hitches, full DeeZee running boards. Factory ordered/delivered Jan 93 has 160K+, it's basically a stock truck with all the Ford options, just no disc player.
Toys: 26'Jayco FK TT, 18'Sylvan Pro Fish.
This may seem like a dumb question, but how do you bleed the system as you spoke of. I purchsed the installation kit, replaced the o-rings, brass washers, and installed new caps and lines. I tried to start the engine and it tried to turn over, then coughed out. I've tried several times to start the engine but she won't turn over. Suggestions???
Your truck should crank back up by holding the gas peddle to the floor while cranking. that should get the air out that got in by replacing the return lines.
Thanks,
J.R.
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Crack open the hard fuel line fitting at the injectors. Open a couple lines and crank it over until you get some fuel out of the fittings. Tighten those back up and move to the next two. Open the next two and again, crank until you have fuel coming out and re-tighten. Be careful not to overheat the starter. Now try to start. If it won't start, move to the next two injectors. keep repeating the steps above until it starts. You may want to wrap a rag around the injectors you are bleeding so you don't make a mess. Tim
Linear Mode
