2nd Gen Non-Engine/Transmission busted fuel line

[CKelly]

there are two lines on the side of the injector pump one with a thick head bolt and one with a thin head bolt the one closest to the front is broke it goes toward the fire wall but i can't see from therehas anyone changed this and how har is it?

 

[MAllen]

the one that returns to the fuel tank is the lower pressure return line. On my truck it transitions to rubber via a hose clamp & I had a leak develop in the rubber part. The rubber part was a snap to replace with a new line in about a hour. Is that the line your talking about?

 

[Vaughn MacKenzie]

Yes that is your return line (this one? #ad
)
I have never heard of that one breaking, unfortunately it's a bit of a job to replace. There is a bolt w/8m head as I recall that secures it at the back end of the injection pump on the engine side. . . it's a bit difficult to get to, and it's kinda long. Next there is a bracket bolted to the head near the filter canister, remove that too, then disconnect the return line there. Then you may be able to fish the metal & rubber return line out.

To make this job easier you might remove the fuel filter assembly from the engine so you can get at it a little better. Might be helpful to read this: TSB 14-07-96 Rev. A
Be sure and put a new good quality diesel rated rubber line on while you are doing this! LarryB has the right fuel hose: LarryB's Dodge starting problems solved here.