literally in the middle of a diesel purge and problem with fuel return hose...
 

Ok I set up everything, bottle is snug in there with the supply going from the bottom of bottle into the inline filter. Now Im trying to disconnect the return hose so I can put the "new one" in but I cant seem to get it off!! I loosened the banjo bolt completely - even took out its screw, but I'm tugging on it and it won't seem to slide off. Should I just keep trying until it comes off? I even disconnected one of those bolts on the fuel filter to push away one of the wires that seemed to be up against hte return hose, but that still didn't help.

I cant see how its possible stuck on?

Get a flathead screwdriver and carefully work the hose back (off) while pulling on it with your other hand. Be careful not to slice your hose (or your fingers) while using it.

Scott

I finally got it off!!!.

While attempting it though, I had to take out 2 of the 3 bolts on the fuel filter and move the hoses out of the way. These bolts have holes on the inside - I assume they are supposed to match up with the holes on the fitting? I just put them back on but I have no way of knowing if they matched up. Is this bad?

they are called a banjo bolt. the hole lines up with a groove (i think) that is the complete circumference where the hole is. nothing to line up just put em in.

Make sure you replace the crush washers on the Bonjo bolts or you will have a massive fuel leak.............. personal experiance

ok just succesfully did the purge. Saw some nice white smoke when i quickly revved to 3-4k. Right now im letting the system cool a little and then i'll change the fuel filter (the spin-on , already changed the inline). I filled the new fuel filter with diesel purge as i don't have clean diesel readily available.

I hope I don't get an air problem after I change it- hope someone can help me if i do!

And the two O-rings .. they both go under the bolt that holds up the filter?

thanks)

why would i have to replace the crush washers? They actually looked brand new and I put them back in the right places. Theres actually two per bolt - one on each side of the banjo.

If it's not leaking, good for you. Those crush washers deform to seal the union. Typically they don't deform sufficiently a second time. Keep an eye (or nostril) out for leaks. If it's not leaking now, at worst it'll seep. It shouldn't blow in a big messy way.

Sixto
93 300SD 3.0 - comatose

Because crush washers are only ment to be used one time. When you use them they mash together to act as a seal. Since they are obviously metal, they wont go back to there original form making them usless. Seeing as they cost about 2 bucks for a pack of five, its probably alot better then having diesel fuel all the place


Just trying to give you advice based on my own personal experience