Need fuel line identification help on 03

[Blakers]

I'm trying to identify which fuel lines are which. Along the frame at the front end of the fuel tank are two fuel lines - one about 3/8 (top) and one about 5/16 (below). I'm assuming the smaller one is the return line.



Anyway, the smaller line has been rubbing on the fuel tank since new and has worn a small hole into the line so it drips fuel oil. I slit a piece of rubber hose and clamped it over the hole and got the leak to slow down, but I have to fix it tomorrow after work. It's right between the tank and the frame with no room to work.



If I loosen the bolts holding the straps for the fuel tank, will I be able to pull the tank away from the frame enough to get in between to work on it? If that is just the return line I should be able to cut the bad spot out with a tubing cutter and put a hose in between.



Any ideas?



Thanks

 

[RDeFayette]

If you looseing the clamps on the tank it'll fall all by itself! At least down to how far you loosen the straps. Take the filler neck loose also.

Put a jack under the front of the tank, take that strap off.

Loosen the rear strap (don't take it off) and "swing" the front of the tank towards the driveshaft. should give you enough room.

You might want to wait until you get the tank pretty empty.

Makes it alot easier/lighter.

Diesel weighs 7. 2 lbs/gallon +/- depending on temp.

Do the math.

The smaller line is the return.

 

[Shadrach]

This is my 03 sending unit. The line with the brass fitting is for my Espar.



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Shadrach

 

[Bob4x4]

You may find it easier to lift the bed to work on the fuel lines/tank. The design of the straps and lack of working room with the tank in your way

will make it a pain especially if you have not dealt with the tank before to be familiar with how it all fits together

 

[Blakers]

Thanks for the advice guys.

I was able to repair it today in about an hour without removing the fuel tank. First I separated the fuel lines and the brake line that runs parallel to them so I could get my stubby tubing cutter in there and cut off the return line just ahead of the tank, and then about 3" ahead of that. I then straightened out the bends on about 4" of the line toward the tank so I could see where the line was worn through. I then slipped a piece of 5/16" fuel hose over the steel tubing back about 2" past where the hole was worn through and put a hose clamp on. Then cut and pushed the hose onto the forward part of the steel tubing and clamped.

So rather than cutting the steel tubing behind the worn spot (which to do so would have required moving the fuel tank out of the way), I just slid the hose back over the worn spot, thus isolating it from leaking.

The hardest part was tightening the hose clamp behind the tank. Had to reach over the frame and come down from the top with a short 1/4" socket.

The leak is now stopped!

Blake

 

[rbattelle]

I then slipped a piece of 5/16" fuel hose over the steel tubing

Did you use a hose compatible with biodiesel?



Irrelevant if you never plan to run biodiesel, I suppose.



-Ryan

 

[Blakers]

Did you use a hose compatible with biodiesel?



Irrelevant if you never plan to run biodiesel, I suppose.



-Ryan

I asked them and they said "yes".