I replaced the injectors on my 92. My son in law helped take out the old ones. I didn't realize how much he had mangled the return line. Now impossible to line up all 6. Tried to bend back into shape.

What is the pressure in these lines? I was thinking of cutting out part of the hard lines and replacing with fuel hose. Would be easy to get banjo bolts screwed in.

My 2003 Sprinter diesel has fuel hose between the return line banjo bolts. Works fine

Think this will work?
I need to get the truck back on the road - I need it Monday
Thanks in advance

 

Anyone? Weather good today for working outside.
Trying to get truck back on road?
Thanks

 

can't say on the pressure for sure, couldn't be much . Are ya having problems lining the bolts back up to the holes without cross threading? I had that problem last time i took mine off.

 

Thanks hounddog
Lining up banjo bolts is the issue. Can get 2 or 3, but not all.
I've tried everything.
Thats why I wanted to put in fuel hose.

 

i don't think there would be enough pressure to worry about replacing them w/ a good quality rubber hose rated for diesel, esp if you use some clamps on either end of it. The ford's used to "daisy chain" their returns together w/ rubber hoses as well, they were well known for rotting out and needing replacing tho. I'd say go for it and just carry some extra rubber tubign w/ you just in case something happened while you were on the road. JM2C

James

 

Thanks James
I'm about to cut - can't get them lined up
Cheers
Jim

 

Why?

 

Vw uses rubber lines on the injector returns on the 1.9 tdi not sure how much pressure a return on a 12mm ve runs tho.

Sent from my DROIDX

 

Thanks moparbubba,
I cut the lines and installed my fuel lines to connect the back three injectors. Got the banjo bolts installed , bled the system and started the truck. I put clamps on the one line that leaked. Other line didn't leak.
For now I used regular fuel line. Need to route the lines up away from exhaust manifold
Cheers
Jim

 

I know MB & VW use diesel rated fuel hose.

I think Cummins use's steel for a reason. Im thinking heat!!!!!!!

 

you can use a good rubber hose and spring clams will be fine I believe that Chevy 6.2/6.5 return line and clamps are real close to that size

 

Thanks bobva and rebal
My buddy runs a Mercedea shop and he can get me right hose. I added a little extra hose so it arches up (a little) over the exhaust manifold. No dealer had the return line - so I'll see how this solution works.
Cheers,
Jim