Replacing fuel lines and injector O rings - Diesel Forum

dugby · 09-20-2007, 06:19 PM

I found some leaking injectors today.the one on the passenger side in the back was leaking bad. It looked like a job that I couldnt handle very well. I brought it to a Ford dealer. They said they had to take all the injectors out. And the rail of lines to work on them to replace lines and O rings. Sound right? They said sometimes the injectors break during this. they gave me an estimate of $700.00. Does that sound fair. I am new to the diesel world and so far I like them. I am learning alot from this sight. Doug

farmfuel · 09-20-2007, 09:20 PM

I bet if you clean it, and look closely at it, you'll find that the injector return bung is leaking. This is the little round piece of plastic that has two small hoses coming off of it. You didn't say the year of your truck, but somewhere around 93, the hose diameter changed from 3/16 to 1/4. Inside this small, round piece of plastic, there are two o-rings. On my truck, this is what was leaking. All you need to do is replace the two o-rings under this little return fitting. Go to ebay, and type in "injector return, 7.3" and you will find all 16 of the o-rings, 8 of the return fitting bungs and all of the hoses and clamps that you will need to do the job. (About 35 bucks) The tools that you will need are a 5/8 open-end wrench, a pair of needle nose or duckbill pliers, and a scribe. lube the o-rings with fuel prior to installing them on the injector. You can blame this leaking problem on the tree-hugging ULSD fuel formula.

dugby · 09-20-2007, 09:55 PM

It is a 1993. I am letting Ford do it because I need to pull my camper this weekend. I have to work. I like to do my own repairs, But this time i have to bite the bullet. Thanks for the info.

Mr_Roboto · 09-20-2007, 10:50 PM

You can change the injector return cap O-rings in about 20 minutes easy.

Loosen the injector line nut, pull all the return caps off, break off the old O-rings with a dental pick, and put the new O-rings on. Make sure you lube the O-rings with petroleum jelly or the caps may cut the O-rings.

DO NOT have the dealer do the job. They haven't worked on IDI's in 10 years and my bet is they will screw things up until you DO pay the $700. It's a very simple job that any shop can knock out in 30 minutes or less.

peejcj8 · 09-21-2007, 10:35 AM

The return line o ring kit cost about 40 buck and is real easy to do, like said.

cdnsarguy · 09-21-2007, 11:35 AM

A lot less for the kit at Midwest fuel injection.......

Weezer · 09-21-2007, 01:51 PM

Sheesh, Doug- where are you in MN? Heck I'd do it for you for parts and a case of barley pop!

Keith

dugby · 09-22-2007, 02:11 PM

I got hosed by the dealer. I didnt have much choice.The time frame was small and I had no time. The parts were less than 50 bucks.The embarassing part was the labor.Please dont give me too much grief.It was $600.00 I know it is bad. I had a hard time writing the check. I wanted to have a talk with the manager but i would have gotten in trouble. Be easy on me I am new to the Diesel game and trying to learn as much as i can. Thanks for all the help.

cdnsarguy · 09-22-2007, 02:22 PM

It was an expensive lesson, but you have at least learned it.... Now you will know to ask here first for anyone in your area be it a Diesel shop or a fellow member to assost you....... I would still visit the dealer and talk with the manager...... I do not know what hourly rate is in your area, but 5 hours is way to much time. Good side is if any problems arise you can go back and rape them over the coals....

arthurgoboom · 09-23-2007, 04:55 AM

Does anyone have access to one of those books that tells how much time it should take to perform a particular task? If so, maybe you could look up the standard rate for this job for Bursch, he can check on the labor rate at the dealer, and if the numbers show that the mechanic took 15 coffee breaks, he could go back armed with this information for a partial refund...