RavenTBK
Full Access Member
*Moderators Note: Thanks to RavenTBK for a nice run down on how to replace your aging return lines. This author's presentation presents a popular way to do this process.*
Here is a quick rundown, how-to, directions, whatever you want to call it about doing your own injector return lines in the driveway. There are many many threads out there with valuable information, but really isn't anything with pictures to get a timid wrench like myself the confidence to just go knock it out. Now that you see generally whats involved, go back to searching the forums for good info and tips.
Click on any inline image to enlarge...
Lets get started:
1. Get yourself a quality return line kit. Send a PM to either "typ4" or to "agnem" to get one. Current price (obviously can change) as of this writing was $51, shipped. Verify through PM before you ***** about it.
2. Get comfortable... in my case, required a fan hung up to keep the 'squitos off my ass. Laid down a ladder across the front end to make it easier to lay up there.
3. Get your tools. Specifically you'd need:
5/8 Line wrench
Flathead Screwdriver
adjustable wrench
standard socket set (1/4" drive preferred due to space restrictions)
Sharp knife (for cutting line)
needle nose pliers
Vaseline (to lube o-rings)
and common-sense.
4. Pull off the aircleaner, set to nicely out of the way.
5. Remove all four (4!) injector line clamps... set them off to the side.
6. Pick a side.. do one half of the engine at a time. I started on the drivers side. Put your 5/8" line wrench to work unscrewing the injector caps. Use your needlenose to slide back the clamps on either end of the unit.. the metal tee on the rear, and the injection pump. Pull the hoses off their endpoints, but leave them attached to the plastic tees.
7. Once all four caps are loose and free, gently pull up on each plastic tee and remove it from the injector. It helps to lightly twist to free them. Try to remove all four tees and lines as a single unit. You will need to put pressure on the hard lines to make room to remove the tees. Gentle pressure, do not bend! In my case, the return tees were original parts, and FIRMLY attached. I used the flathead screwdriver to assist the tees in popping up.
8. Once all four tees are out, lay them on a flat surface to inspect, and recreate them out of new parts. Measure the hose length between each plastic tee, and recreate it with new parts alongside. Basically build a new four tee "unit" alongside the old one. You can see my old tees were so old and brittle that they didnt survive removal as a unit. The important part is getting the hose length correct in between the tees.
8(a). On a side note, if your lines are excessively old like mine, you might have trouble removing them from the metal parts. This is a closeup of my metal tank return tee. The hose is basically turned to rock and had to be whittled off the nipples. Holy crap. Don't be afraid to deviate from these instructions slightly to accomplish the goal. I had to undo intake manifold bolts to free up the tee to cut them all off.
Edit: There are more steps in the writeup... waiting for a mod to approve the second page... it should appear below this one. Sorry@! -rTBK
Here is a quick rundown, how-to, directions, whatever you want to call it about doing your own injector return lines in the driveway. There are many many threads out there with valuable information, but really isn't anything with pictures to get a timid wrench like myself the confidence to just go knock it out. Now that you see generally whats involved, go back to searching the forums for good info and tips.
Click on any inline image to enlarge...
Lets get started:
1. Get yourself a quality return line kit. Send a PM to either "typ4" or to "agnem" to get one. Current price (obviously can change) as of this writing was $51, shipped. Verify through PM before you ***** about it.
You must be registered for see images attach
2. Get comfortable... in my case, required a fan hung up to keep the 'squitos off my ass. Laid down a ladder across the front end to make it easier to lay up there.
You must be registered for see images attach
3. Get your tools. Specifically you'd need:
5/8 Line wrench
Flathead Screwdriver
adjustable wrench
standard socket set (1/4" drive preferred due to space restrictions)
Sharp knife (for cutting line)
needle nose pliers
Vaseline (to lube o-rings)
and common-sense.
You must be registered for see images attach
You must be registered for see images attach
4. Pull off the aircleaner, set to nicely out of the way.
You must be registered for see images attach
5. Remove all four (4!) injector line clamps... set them off to the side.
You must be registered for see images attach
6. Pick a side.. do one half of the engine at a time. I started on the drivers side. Put your 5/8" line wrench to work unscrewing the injector caps. Use your needlenose to slide back the clamps on either end of the unit.. the metal tee on the rear, and the injection pump. Pull the hoses off their endpoints, but leave them attached to the plastic tees.
You must be registered for see images attach
7. Once all four caps are loose and free, gently pull up on each plastic tee and remove it from the injector. It helps to lightly twist to free them. Try to remove all four tees and lines as a single unit. You will need to put pressure on the hard lines to make room to remove the tees. Gentle pressure, do not bend! In my case, the return tees were original parts, and FIRMLY attached. I used the flathead screwdriver to assist the tees in popping up.
8. Once all four tees are out, lay them on a flat surface to inspect, and recreate them out of new parts. Measure the hose length between each plastic tee, and recreate it with new parts alongside. Basically build a new four tee "unit" alongside the old one. You can see my old tees were so old and brittle that they didnt survive removal as a unit. The important part is getting the hose length correct in between the tees.
You must be registered for see images attach
You must be registered for see images attach
8(a). On a side note, if your lines are excessively old like mine, you might have trouble removing them from the metal parts. This is a closeup of my metal tank return tee. The hose is basically turned to rock and had to be whittled off the nipples. Holy crap. Don't be afraid to deviate from these instructions slightly to accomplish the goal. I had to undo intake manifold bolts to free up the tee to cut them all off.
You must be registered for see images attach
Edit: There are more steps in the writeup... waiting for a mod to approve the second page... it should appear below this one. Sorry@! -rTBK
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