Anyone ever pop the plug on one of their rear injectors before? Noticed a fuel smell the other day so I popped the hood and noticed fuel leeking out the drivers side rear injector. Turned out to be a $2.75 injector plug. Not worried about the cost to replace it but it kind of makes me wonder if I'm running elevated fuel pressures I should be concerned about. Maybe a restriction somewhere in the fuel return? What do you guys think?

Are you talking about the rubber plugs that would normally be connected to the fule return line on the other injectors? If so, then yes, I have had one pop off before. They will deteriorate with time and need to be replaced every few years, just like any other rubber part that is exposed to fuel and air.

Yeah, I've had that problem. No big deal... They fail fairly frequently on these old trucks. The rubber doesn't stay very nice when they get this old.

When I get around to fooling with my "new" IP and intake, I intend to replace all of the old rubber in my van's fuel system with Viton to address this problem.

Is there only one correct way to hook up the return lines, and/or a diagram of this ? I recall hearing about people running a line between rear injectors instead of capping them off, but I could be mistaken.

You just hook them up in series. I guess you could hook up both rear ones but then you have another line to get pinched, rub thru etc.

Could you just Tee your return into your supply line before the lift pump? Would that work, or not?

Could you just Tee your return into your supply line before the lift pump? Would that work, or not?

I would say no, as you could slightly pressurize the injectors and cause it to run rich or maybe worse case, hydraulic the injector?

Thanks guys. I didn't think it was anything too serious. Just wanted to check with everyone and make sure. First time it's ever happened on this truck. The funny thing is that the injectors have only been in there for 2 years and 40-50000 Km's (it'd be more but the truck didn't see much action for about a 9 month stretch between a course I did and the time it took for the rebuild).

Could you just Tee your return into your supply line before the lift pump? Would that work, or not?


this would be bad, if ya ever ran out of fuel the pump would suck air from the return easier than pulling fuel up from the tank, I'd guess the air would go round and round up the feed, back down the return and you'd never get it bled.;)

Connecting the return line into the supply line before the lift pump is fairly common practice in the WVO world. Doesn't hurt a thing as long as you aren't getting air in the system anywhere (if you are it gets the system really full of air). I'd say it would work, but I think I'd stick with the stock arrangement.

One reason for the return fuel is to cool the I.P. If you put the return fuel back into the inlet side of the pump, the heat will not dissipate like it will back in the tank. The amount of fuel in the tank plays a role in how much heat is removed from the fuel returned to the tank. The old Detroit Diesel manuals used to advise keeping more fuel in the tanks during warm weather to aid this cooling process.