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I've yet to find any black rubber (Viton is the lining on good black rubber fuel line.... Ie 30R9) that works as well as Viton. Both my 6.2's and my old Mercedes diesel ended up with Tygon replacing the black stuff. Ymmv.

^'Return to tank'. I'm really starting to hate this smart phone.

Use Tygon on the injector nipple part of the return system not supply and not after the both sides of the nipples tie into the metal return to talk system . Should need more like 1/8 for return nipples . The supply side and return after the nipples should be SAE 30R9 (the 1/4 and 3/8)

How are you doing on this one? When my truck started fuel problems I used the electric pump to pump out as much fuel as I could. Also there is a syphpon fitting on the original fuel sending units you can use to syphon/drain the tank. heres the thread I started on the process of...

as for the cap, I always figured I'd put a 'Y' in and run both return lines on the last injector fwd to the next through the 'Y'. Just make sure your "Y" is compatible with BIO.

You probably use the clear Tygon. The yellow is used if fuel/oil applications and is what I use. It's always been cheaper than clear when I've shopped it.

^SAE not sale..... Stupid spell check! (ETA: Thanks Warthog... i was using taptalk on my phone... doesn't offer to edit).

Viton is the lining for SAE 30R9 fuel line. Pure Viton fuel line is expensive and typically used immersed in fuel applications. 30R9 is not viable for fuel return lines. The yellow Tygon will do the trick. Take an old injector with you to the small engine shop and slip some over the return...

Google Tygon. It's safe for all fuels. Found in local small engine repair shops and hardware stores. It's not cheap.

I had to switch my return lines to Tygon. No more leaking injector returns.

Dittos!

Buyt the "heavy duty" option for the filter at any autoparts store... the heavy duty = foam ring.

Do always carry extra fuel filter(s) and whatever tools you'll need to change them. Do change the fuel filter(s) first when ever you get a rough running or low power engine and are away from your shop. (my truck has an electric fuel pump mod with prefilter... 90% of my rought running/low...

The Wellmans swell when they over heat, making them very tough to remove. Some folks end up taking the head off just to change a glow plug because they break off in the pre-combustion chamber. The AC 60G's are newer technology, that don't swell, and they self limit (The controller when...

I'd like to dedicate this thread to the discussion of the mysterious little glass ball in the check valve on the top of the IP cover. I did some searches and didn't find one good thread about it. But lots of miss information and various opinions through out many threads. To start this off I'd...

If you do decide to mess with the 24v system, do the roscommon mod, so that you can get ~some~ help from here. (I did it and have no trouble finding starters, and have no worries about glow plug resisters failing and frying my plugs). In addition to the Military TM's Get the Haynes Techbook...

Is your truck stock 24V? or has anything been done to it like a 12 Roscommon mod, or glow plug resister by pass? Like the other guys said... if your truck is stock take the time and follow the procedures in the TM. When you say you bought Glow Plugs... are they AC60G's (the best for your...

The clear hose is the standard stuff you an buy a Lowes or homedepot. Not diesel rated but works. I replace mine every year or two.

You can also put a clear line on the top of the IP to the return system... it will help emensly with noting and diagnosing air in fuel problems. good fuel filter mod thread: http://www.steelsoldiers.com/showthread.php?36435-My-CUCV-spin-on-fuel-filter-mod/page5 electric fuel pump...

Like I posted above, I put one of these Vista Pro's in my CUCV and another in my 87 R20 Suburban... one of them developed a leak at the solder joint (about a year after installed) near the upper radiator hose. Got a replacement (I purchased mine from Advanced with a lifetime warranty)...