Ford International 7.3 IDI 6.9 return lines orings glow plug and harness. Diesel fuel hemorrhage

In depth repair process showing IDI return lines and Orings being made and replaced, also glow plug testing and harness testing.
Links to parts used in this video:
Return line kit, includes everything you need!
amzn.to/3P1elst
Ford Motorcraft glow plugs (the good ones)
Individual plugs if you need 1 or 2: amzn.to/3oYnSWD
Set of 8 glow plugs: amzn.to/3JAkt9X
SUPER LUBE, this is a must for Orings in any application
amzn.to/3piUL0F
Amazon Affiliate Storefront:
www.amazon.com/shop/frostydoesit

[@morgansword]

You bet! I did enjoy even tho I am a diesel mechanic of this era. I am seventy three and haven't turned a wrench now since 05 and that is because I got crippled up bad enough to make it impossible to work anymore. I liked these low power engines, was thinking this was a brick nose, not a OBS truck as I wasn't aware of their carrying this engine to the newer powerstroke engine trucks. I loved the external injectors and glow plugs. That wiring loom under the valve covers is spendy and gets real brittle making it a hard to fix on passenger side with all the "bleep" stuff crammed under the hoods. I was a loner kid cause of being a native... dad had me working in his shop by the time I was eight... I was one large boy who knocked out every kid who teased me. It was apparent that it wasn't going to get better so I never got any schooling till the army drafted me when I was just getting close to eighteen and going to jail for beating a bunch up who thought that because there was five of them, well you know when the first big guy goes down, the rest skedaddle like chickens after a grasshopper. After I got home it was the same thing but different as now I was a baby killer and all sorts of names they called me. I finally went to alaska and worked as a mechanic till a few accidents made it hard to get hired on. Work had slowed down in the southeast. I came to anchorage where I owned my own shop. That shop is still going even after I sold and went to the valley to just work on my own toys. Like said somewhere, I was ford cause everyone else was chevy or dodge. I had acquired a few of these trucks with the IDI engines. Because of rust on their cabins, I stripped those bodies off and replaced them with guess what, old chevys or dodges. I had all of them fairly easy starting as I changed little things like those return lines I made copper lines that couldn't leak as there are different tops to those injectors and the ones with metal tops lend to doing just that. I had a fifty ford which was a real hard squeeze to install a cab over the mass of this engine but a grain truck, a 57 C 60 I think was the model number on it. Then came a 55 dodge ton and a half with all ford running gear as the others were. All were also 4X4 so it made it so much fun to drive them. I had a older truck of mine setting in front of O'REILLY'S and a guy comes in and asks around to who owned that truck and I raised my hand. He offered me some really good money for it and it should of went home with him.,.. I didn't know him so just said no. Us older mechanics in the southeast were also fabricators or you were out of work because of no parts out on the islands, you just made things work regardless of what it took. I was really dang good at that. I just loved working by myself as marriage was also not my long suit. Its real hard to fake what you don't have a clue about like how to be a good husband.... I thought as long as I gave her the check, things were good.... she told me that if I had ever shown some emotions that she would stay... I let her go, sorry for that now but that is that. I have a dog, or he has me... kind of a win win for the two of us. I just wish they lived longer. These engines were no power houses but boy howdy, they just ran forever. I hope this comment wasn't too boring and will be looking forward to your other projects

[@frostydoesit]

Hi Morgan! Thank you for watching my video and for taking the time to share some of your story/life with me. It sounds like you have experienced a lot in your life and you would be a guy I'd like to sit down with some day and have a cup of coffee or a drink with. I am sure there would be lots of great conversation!! Thanks again for taking the time out of your day to say hello! -Frosty

[@JeremiahsGrotto-ok7ed]

Thanks for sharing ... Take care of yourself...✝️

[@oby-1607]

Great video. My nephew just got a 7.3 idi and we need to know all the things to keep it running efficiently and reliably. Thanks.

[@frostydoesit]

You're welcome, thank you for watching! Please consider subscribing for more videos on this truck!

[@ydocproductions5593]

I watched the whole video series on this 7.3 IDI, and it’s a very cool project truck man! I liked your process of how you diagnosed each problem step by step. You have a cool channel keep the videos coming!👍

[@frostydoesit]

Thank you for checking them out & for the sub! I appreciate it a lot! I'll be checking out your 7.3 project tonight!

[@jamesmcnamara7484]

I scored a 94 IDI Turbo with 150k on the clock for less than $8k I’m happy with the purchase, but it must have been parked in hells side yard. Everything rubber turned to plastic long ago, everything plastic has become brittle. I have a lot to learn, thank you!

[@frostydoesit]

Sounds like you found a good project. The older Fords are tough and reliable and worth putting some $ and time into. Thanks for watching and taking the time to comment! -Frosty

[@loreto220ify]

Great video just what I was looking for not very mechanically inclined but definitely gonna try this on my 88 7.3 idi hopefully it helps with my hard starts

[@frostydoesit]

Thanks Anto! Hope it gave you an idea how to address some work you wanted to do to your idi. Thanks for watching and let me know if your truck is easier to start once you finish! -Frosty

[@BungalowBrilliance]

thank you so much for the walkthrough on this. As someone with minimal mechanic knowledge this has helped me immensely to understand the parts I need to check and ways to ensure my 92 7.3l idi is running perfectly.

[@frostydoesit]

You're very welcome! Glad it was helpful and thanks for watching and taking the time to let me know you enjoyed it! -Frosty

[@josesmoya]

Excellent job. Congratulations!

[@frostydoesit]

Thank you very much!

[@petterblack6459]

Excellent video you explain very well and you show him installing everything

[@frostydoesit]

Glad it was helpful! Thanks for taking the time to let me know you enjoyed it! -Frosty

[@stevenmchenry9276]

Frosty thanks for the video. I'm trying to get my truck going.

[@frostydoesit]

No problem, I hope it helps you get yours going! You can do it! -Frosty

[@Drummavirus]

Thanks for the video boss! About to do this myself!

[@frostydoesit]

No problem 👍Thanks for watching!!

[@lauramilan1]

Love this!!!

[@frostydoesit]

Thank you!

[@RollingRigTraction]

I will be doing the fuel return lines as I have at least two injectors leaking right now. Along with the new glow plug controller parts and all 8 glow plugs cause it's just as cold blooded as my '84 was. I had to start it last night to extricate the truck from a flooded field so the police officer that was coming by to do a VIN inspection on it didn't have to go slog through the mess. My shoes were like swamped boats, the water was about a foot deep in places! Just didn't want to start and I just about drained the batteries, luckily I had a can of starter fluid in the van so I got it running, truck then wouldn't move, had to get back out into the water and go engage the front hubs and give it a bunch of throttle to get it free if the sinkhole it had settled into! The cop was appreciative and I won't be parking it out there again!

[@frostydoesit]

That's quite the ordeal you had to go through to save the cop from getting muddy shoes! These IDI sure start better when the fuel system is leak free and air tight along with functioning glow plugs. Thanks for watching and taking the time to comment!! -Frosty

[@mooresey009]

Thanks a lo5 for the Video! Going to have a crack at this tomorrow.

[@frostydoesit]

It was pretty easy, anyone can tackle it!

[@davidburke1794]

I found the hard way, replace all glow plugs at the same time. Also, the controller might need to be replaced if more than 2 glow plugs are dead when testing. The miss match loads will mess up the controller and will lead to early plug failure.

[@frostydoesit]

Thanks for the advice! I did have only one glow plug that was bad, the other 7 all had the same resistance, I got lucky.

[@papabigballs3288]

Bypass the controller with a switch. Thank me later.

[@rc5693]

@@papabigballs3288 better yet install 7.3 idi controller and glow plugs, you will have to change connectors to glow plugs but the 7.3 ones carry more amperage and are better made

[@ReindeerBork]

Nice video

[@frostydoesit]

Thank you! I appreciate you taking the time to let me know!

[@wolfshedler5898]

i put in a fuel solonoid shut off valve in the final return line . No more fuel leaking back to the tank

[@frostydoesit]

That's an awesome idea! What part/model did you use?

[@st-jeanstephane7876]

excellent travail compétent JAI possède 4 diesels 1986 1990 1988 1989 très satisfaits 👍👍 6.9 et 7.3 tre bon moteur

[@frostydoesit]

Yes, they are very good reliable engines. They make decent torque and last a long time. Thanks for watching!

[@heidislz]

you can test glow plugs before removing them. simple test light from positive battery terminal to plug terminal. Ignition switch in off position

[@frostydoesit]

That'll work if all you want to test is if they are making continuity and aren't open.

[@heidislz]

just got my really cool ford manual today and I was wondering about that same thing. It doesnt however say anything about ohm readings. So far 3 of the plugs test good just from a continuity standpoint , but thats far from definitive. Any thoughts? @@frostydoesit

[@RollingRigTraction]

Autolites would burn off the tips, they're always far cheaper than any others. Unfortunately both IDI's I've had had the glow plug controller bypassed to a push switch. I had the first one set back to original and intend to do that with my new one also. To note there are two different styles of glow plug for the IDI the bullet style like you have there or the blade style connectors.

[@frostydoesit]

I agree with you, Ford/Motorcraft glow plugs are the only way to go.

[@RollingRigTraction]

@@frostydoesit despite my dislike for most things German especially when it comes to automotive I have had good luck with the Bosch glow plugs, the one time I used them to replace the Autolites after learning they were problematic. I've gone with the Motorcraft glow plugs with the new truck project and intend to stick with them. Now I need to find an oil dipstick and pray it hasn't been too low on oil all this time!

[@frostydoesit]

@@RollingRigTraction I've used Bosch in the past as well with good luck. Any glow plug that days "Beru" on it seems to be a quality part.

[@RollingRigTraction]

@@frostydoesit good to know, I just found that AC Delco also manufactures them. Could possibly work in a pinch...

[@kevine3634]

What if the glow plugs aren't receiving a consistent reading of 12 volts? After turning the key to the on position, I half expected the glow plug relay to express 12 volts and am only getting about 10 volts to the relays transfer of power and then it appears as though the wire going to the glow plug is only receiving a variable 8 to 9 volts...with an occasional 10v reading.... never 12 like I think I should have.... Where am I going wrong in identifying the crank no start on an 1987 f350 flatbed custom dual real wheel automatic 6.9 diesel idi? Advice and criticism welcome!

[@frostydoesit]

The glowplugs aren't going to get 12v when the battery is supplying all 8 of them. There is a massive current draw when they are on, and I am sure the voltage drops below 12. Check the voltage directly at the battery while the GP are on, see what it drops too. You may have poor wiring with high resistance between the battery and glowplugs too.

[@MrHighschoolwrestler]

I got a 93 idi I just replaced my lines and a few caps leak. So I probably need to put that washer on?

[@frostydoesit]

If your cap is leaking it could be from a few things, o rings rolled or got knicked....did you lube them up? Could also be from misalignment if the return lines aren't the correct length....a washer on top of the cap will usually help straighten it up and fix a leak. Guys will say it's a bandaid to use the washer and you should fix the root of the problem. I have washers under a few of mine to keep the cap seated perfectly. Good luck and thanks for watching! -Frosty

[@robertshields3912]

Can I use silicone spray lubricant instead grease , wasnt able to find it at local part stores in Alaska?

[@frostydoesit]

Silicone should work fine

[@cgentle19]

How did you bleed the lines? I’m not a mechanic but I’m fixing to try and get my late father in laws 93 f350 7.3 idi back up and running after sitting for a couple years. It was parked bc we was having a lot of trouble getting it started

[@frostydoesit]

crack the nuts loose at each injector while you crank the engine, that will bleed the line of air all the way up to the injector.

[@mr._gator1284]

I’ve got the original slave lake 2.0 😂 I’m currently rebuilding the motor tho😂

[@frostydoesit]

sniff too much summer air?

[@mr._gator1284]

@@frostydoesit about 2 cases of Cosby in a can

[@tommicruiser6904]

Well these glow plugs work in 1983 6.9 idi also?

[@frostydoesit]

They will physically work in your 6.9 but I believe the way the wire hooks up to the top of them are slightly different and you may have to adapt your harness to get them to work.

[@greenmtnman7714]

I have a 1987 F-250 which I ordered new. I have never messed with the fuel line clamps when doing this. Not trying to start an argument, just stating facts.

[@frostydoesit]

That's awesome that you haven't had to!

[@greenmtnman7714]

I think you did a good job here. I also never used silicone grease until the last couple times.

[@edwardsmith7160]

Hey thanks for the video I got a 1990 ford idi you think this kit would work for me

[@frostydoesit]

Yeah I think it would, they make two different style caps that go over the injector. Just get the kit that places the nipple in the same position that yours are in.

[@edwardsmith7160]

Hey you think you can give me a call I’m having issues I can send you a video

[@RollingRigTraction]

@@frostydoesit apparently they are also different return line caps with three line connections for the turbocharged engines.

[@johnminnick1228]

I was taught to always replace all glow plugs when swapping due to wear and tear so all the glow plugs have the same resistance and draw the same current what was your logic behind making an expection here? I would really like to know bc it could save me money on my 86 idi

[@johnminnick1228]

- a guy who JUST replaced all 8 glow plugs even though only 1 was bad

[@frostydoesit]

Great question, I think most people assume if 1 or 2 are bad the rest are not far behind. Before I replaced just the 1 in this video I did ohm/resistance check all 8. I k ew I had one with an open circuit and the rest of them all had the same low resistance so I kept them. I also believe that if something isn't broken or worn out (and it's easy to get to) that I am not going to throw money away just to pull the trigger on the parts cannon. That's just the way I operate with mechanical things. Thank you for watching! -Frosty

[@ivanreyes1946]

HELLO SIR I HAVE A 1993 FORD F350 7.3 IDI THAT WHEN IT GETS HOT ITS REALLY HARD TO START

[@frostydoesit]

Sounds like it's getting air in the lines, what have you done to troubleshoot it?

[@ivanreyes1946]

@@frostydoesit I am new to diesel I took it to my mechanic and he never fix the problem

[@frostydoesit]

@ivanreyes1946 thats too bad, hipe you didn't pay him if the problem wasn't resolved

[@ivanreyes1946]

@@frostydoesit IN THE MORNING THE TRUCK STARTS RIGHT AWAY AND THEN I GET TO WORK AND TRY TO START IT TO GO TO THE NEXT JOB, THATS WHEN STARTS HAVING ISSUES, WHERE CAN I START TO TROUBLESHOOT THE PROBLEM

[@rafaeldominguez2472]

I have a problem with the return line why one of them get to hot an burn the plastic of the return line

[@frostydoesit]

Did you figure out what got it so hot?

[@rafaeldominguez2472]

@@frostydoesit nope maybe cause I plug the electricity on the gloves outlet

[@rafaeldominguez2472]

Glogles

[@rafaeldominguez2472]

I also take of the inyector and look bad little bit

[@paulm.6437]

Watch Wes Work, yes

[@frostydoesit]

I enjoy his channel too!

[@fredwilley3886]

Can't stop return line o-rings leaking.

[@frostydoesit]

If you get the hose between injectors perfectly straight (I didn't get this perfect in the video) they usually won't leak. If they still do put a washer on top of the plastic hat , that helps them sit straight.

[@fredwilley3886]

@@frostydoesit thanks

[@frostydoesit]

@@fredwilley3886 you're welcome! Thanks for taking the time to watch and comment!

[@FirstGendodgegarage]

id be swapping those spring clamps for real hose clamps for sure

[@frostydoesit]

Ah they were tight enough 😆

[@justinsjourney431]

29.15. And on today’s episode of.. “Where not to insert your pecker”

[@frostydoesit]

HAHA RIGHT! Keep it far far away from that tool!

[@FirstGendodgegarage]

sorry but 12;19 had me howlin pal

[@frostydoesit]

Wood woooo

[@ryanpolzak5014]

Did nothing to show bleeding process

[@frostydoesit]

There is no bleeding process. "Bleeding" was in refence to how bad they were leaking.

[@64maxpower]

None of that looks easy to me

[@frostydoesit]

Easier now that you've seen it done!! It's really not all that bad. Thanks for watching!! -Frosty

[@64maxpower]

@@frostydoesit I almost don't have a choice. I can't find anyone willing to work on it. It's on me. I appreciate you making the effort to video and upload

[@frostydoesit]

@64maxpower you can definitely do it! I put amazon links in the video description for the parts you will need. Take your rime and get the parts 1st and you can knick it out.