leaky injectors

[IH1206]

Im a powerstroke guy so i dont know much about IDI's. Any way I had 5 injectors leaking around the return lines on my uncles truck, so i replaced the o rings in all the injectors. well after firing it up i still have 3 injectors leaking, so im lost hear on what more to do by the way this truck has 138,xxx miles on it and its a 93 250 4x4. If theres any tricks that i dotn know about im all ears to any suggestions. -thanks wyatt

[9ENGEL]

Either the caps aren't all the way on, did you hear the click?, or the O-rings got nicked on installation, did you lube them?. Another possibility is the caps are cracked. Its best to replace all the parts- O-rings, caps, and hose.

[cdnsarguy]

Leakers on a completely new set of orings, caps and return lines is most likely not seating the caps fully........

My personal advice is NEVER just change the orings on any old sets over a year old (unless an emergency). The caps can distort with the heat over time and you may never get a good seal.

These folks are good to deal with.... not saying that your local IH or diesel shop won't have what you need, but price and availability is a factor to most here..

http://www.mwfi.com/dieselPage/ford_69.htm
http://www.mwfi.com/dieselPage/ford_73.htm
http://www.dieselpage.com/dlk.htm


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.