Hi all, I am working on replacing all my fuel return lines and seals on my 90 F350 IDI 7.3 to fix my air intrusion problems. I got a kit from Pensacola Diesel and all is going fine but I do have one question. What are the eight copper washers for that are in the kit? I didn't have anything like them on the injectors when I took the fuel return lines apart. At first I thought they might be intended to go on top of the return fittings on each injector but the opening in the copper washers is too small to fit over the threads. Anyway just was hoping someone could clear this up. Thanks.. Jay

 

its a whole injector install kit.
those washers are used when replacing the injectors.you wont be removing the injectors,so you wont be using those washers.
if you haven't installed the O-rings on top of the injectors yet,you may want to consider installing Viton O-rings instead of the ones in the kit.

 

If you are using the o-rings in the kit you are likely wasting your time ... some (including I) have had much problems with them, they are GARBAGE!

Get some Viton Return O-Rings - McMaster-Carr Item 9464K24 and you'll be much happier.

-Enjoy
fh : )_~

 

Thanks Ford250 & Festus. Glad I didn't overlook something. I have already got all the kit O-rings, return caps, and hoses installed now. I will go on and pick up some of the viton O-rings so I will have them for the next time. I don't do a lot of over the road travel with this truck and mostly use it on the farm and local areas for hauling rock and dirt. Just wondering since this is my first experience with IDI 7.3 and my first experience with air intrusion.... How long will a reseal job on the fuel return system usually last?

 

Festus, that's a really great deal on those viton 111 O-rings you linked in your reply. For what its worth, after doing this job the first time the installion kit wouldn't be necessary in the future. I now have a whole set of injector cap return tee's that all seem just fine to use again. With a 50 pack of viton O-rings, a length of bulk hose, and the remaining (good) clamps from this time I'll be good to go for the next time when it happens. From reading through the threads so far it seems like air intrusion is a common problem on this IDI 7.3 but I have no idea how often it comes around.