Repair your fuel injector return line!

Over · **Joined:** Sat Apr 25, 2015 10:34 am **Posts:** 34

New injector return line: about $60

Repair kit: $22.5

I'll just leave this right here: http://www.ebay.com/itm/6-6L-Duramax-Injector-Return-Line-Kit-6-6L-2004-5-2010-/151610155396?hash=item234cab6184&vxp=mtr

thermorex · **Posted:** Mon May 18, 2015 10:29 am

So does this fit the crd injector? That's good to know, as you can buy the return hose for many places, I always wondered what sizes and interchangeability is for the plastic t connectors.

Over · **Joined:** Sat Apr 25, 2015 10:34 am **Posts:** 34

thermorex wrote:

So does this fit the crd injector? That's good to know, as you can buy the return hose for many places, I always wondered what sizes and interchangeability is for the plastic t connectors.

It does. Exact same part for the fittings. They are made in Italy by a company called Redat Manufacturing.

thermorex · **Posted:** Mon May 18, 2015 12:07 pm

Perfect, thanks for sharing

bugnout · **Posted:** Sat Jun 20, 2015 6:26 pm

Thanks for sharing. Just discovered a leak off the top of #3 injector. This is much better than $60 for the assembly

geordi · **Posted:** Sat Jun 20, 2015 6:50 pm

Now if only there was a metal version of the return block, or if these were made of brass AND there was a metal version.

bugnout · **Posted:** Sat Jun 20, 2015 10:34 pm

Agree, This is what I came up with when I broke that piece of ...

racertracer · **Posted:** Sun Jun 21, 2015 1:27 am

BUG, that's not a bad setup either.

Post the material list and how you made it.

geordi · **Posted:** Sun Jun 21, 2015 1:39 am

Yeah, I kinda like that Bug, how'd ya make it?

papaindigo · **Posted:** Sun Jun 21, 2015 9:15 am

A brass option made from plumbing parts can be seen at viewtopic.php?f=5&t=80939&p=853259#p853259

95Z28A4 · **Joined:** Sun Mar 30, 2014 9:53 am **Posts:** 297

geordi wrote:

Yeah, I kinda like that Bug, how'd ya make it?

It looks like a NPT bull plug that was cross drilled completely through. Then, two intersecting diagonal holes were drilled. I assume the NPT threads were cut from the plug? What size plug did you use? And what metallurgy?

bugnout · **Posted:** Sun Jun 21, 2015 11:15 am

Well I got the idea from someone else on the forum. The body is a brass three way 1/4 NPT air hose splitter >LINK<.

Two 90 degree barb NPT fittings for the fuel pump and rail return lines I ordered 1/4 but think I ended up with a larger size>LINK<
One 1/8 straight barb1/4 NPT [/url] for the injector return.>LINK<
One straight 3/8 barb NPT fitting for the outlet to the tank (Think its 3/8 but can't find what i ordered)

I bent a piece of steel and drilled a couple of holes in it to have some where to zip tie the block to the same spot the original mounted
I thought about making a hex bracket of bent sheet metal to slip the body into but got lazy and wanted something quick.

Here's another picture that seems to show I used a larger size

95Z28A4 · **Joined:** Sun Mar 30, 2014 9:53 am **Posts:** 297

Wow!! A compressed air manifold.....that's easy! How about an aluminum log style? The "5th" nole can be plugged with a allen head NPT pipe plug.

http://www.amazon.com/Thread-Quick-Conn ... r+manifold

geordi · **Posted:** Sun Jun 21, 2015 3:40 pm

Ooh, I like that blue one - that looks like it could be a good option too.

And here I was thinking that a prototyper would be useful to scan that thing and duplicate it, when just parts from my favorite auto parts store (The Home Depot) would be everything needed!

Awesome!

bugnout · **Posted:** Sat Jun 27, 2015 7:52 pm

The only thing missing from the kit is the check valve. I just reused mine. I noticed that each of the 3-way fittings is marked as either "3" or "1". I could not detect any difference between them but I matched that to the markings on the originals which were marked 3.1 or 3.3. I used "1" for injector 2 and 3, "3" for injector 4. The connector for #3 was broken off and stuck in the top of the injector. Took a small screwdriver and twisted it until the piece wedged, then pulled it straight out.

This an even better deal because the kit include 4 of the fuel return line clips. They are not stainless like OEM, but spring steel.
The Stainless clips go for $19.95 a piece which means this $20 kit saves you about $120 over OEM parts.

Over wrote:

New injector return line: about $60

Repair kit: $22.5

I'll just leave this right here: http://www.ebay.com/itm/6-6L-Duramax-Injector-Return-Line-Kit-6-6L-2004-5-2010-/151610155396?hash=item234cab6184&vxp=mtr

flman · **Posted:** Sun Jun 28, 2015 6:43 pm

I think the little bobby pins for our CRD are about $20 a piece, this kit is worth having around for any project where you need to remove injectors.

geordi · **Posted:** Sun Jun 28, 2015 10:46 pm

flman wrote:

I think the little bobby pins for our CRD are about $20 a piece, this kit is worth having around for any project where you need to remove injectors.

I call those things the "Oh $#!T" clips, b/c usually when you are grabbing them with the needlenose, they manage to spring loose and you immediately go "oh S#!T, where'd that thing go?" :banghead:

flman · **Posted:** Mon Jun 29, 2015 8:19 am

geordi wrote:

flman wrote:

I think the little bobby pins for our CRD are about $20 a piece, this kit is worth having around for any project where you need to remove injectors.

I call those things the "Oh $#!T" clips, b/c usually when you are grabbing them with the needlenose, they manage to spring loose and you immediately go "oh S#!T, where'd that thing go?" :banghead:

I keep a magnet nearby by after I lost one, and managed to find it in a crevice of the engine, but losing one of then could bring the entire project to a stall. Vice grip needle nose pliers can give you more of a sense of security as well.

flman · **Posted:** Mon Jun 29, 2015 8:27 am

I just ordered one of those Duramax kits to have in my CRD parts arsenal, what is the point in re-engineering a fuel return line on a 10 YO vehicle, unless you are in a pinch and have to do it on the spot?

Besides, that kit may even work on my 2 Sprinters.

dirtmover · **Posted:** Tue Jun 30, 2015 9:03 am

A couple of tips:

- Rodents like to nibble through the OE style cloth braided hose
- 1/8" Tygon fuel and lubricant hose, the yellow stuff, will get you going again at a pinch. You can pick some up cheap at Napa or any small engine repair/parts store.

Repair your fuel injector return line!

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