Engine/Transmission (1994 - 1998) Fuel Leak - help

[PaulG1]

Got a fuel leak yesterday - a small trickle but much faster than a drip.



It seamed to be coming from nearby the fuel filter or preheater and running down the side of the block but difficult to pinpoint because of all the brake lines, etc. in the way.



Symptoms:

Leaks when running.

Does not leak when engine off and ignition key is in run position. (does this rule out the filter and preheater?)





1. What are the most common failed items to check?



2. Does this sound like it is the fuel return line?



Any advice welcome.



Thanks,



Paul

 

[Joseph Donnelly]

It's probably the return line. Since you have a mechanical lift pump, turning the key doesn't help the diagnosis.

 

[PaulG1]

Thanks Joe.



Good guess. After crawling around and turning the engine over to produce the leak, the leak is coming from the fuel return line where the rubber hose clamps on to the steal tube (connection is tucked up under the intake manifold casting on the head). Not sure if the hose is cracked or the clamp failed - probably the hose.



Looks like you've got to be elasticman to get to it. Perhaps removing the starter and fuel filter will make it accessible. Any ideas anyone?



The engine didn't fire when turned over for 4 or 5 cranks to reproduce the leak (I didn't want it to but it normally would have started immediately). Seam's like its not getting fuel - does this sound normal after a leak such as this?



Is there anything that could have been damaged or could air have entered the pump somehow that needs to be purge. I'll need lot's of good wisdom/experience on this part.



Thanks again.



Paul

 

[Joe G.]

You can get more room to work if you lean the master cylinder toward the fender. Remove the two nuts that hold it to the booster. There is enough flex in the brake lines so that the master cylinder can be moved over.

 

[Smokin Dodge]

I just got the same leak on mine today it was the rubber hose behind the fuel filter what a PITA it was to get it off ,mine wasnt just a leak it was more like a diesel faucet, the hose was crakced the whole length I cant believe it just now started leaking.

 

[crabman]

G1,

Is there a West Marine in your area? If so, go there and buy their marine USCG approved fuel hose. Wall thickness is 3x that of regular fuel hose. They also have some SS hose clamps that do not have the slit showing on the inside. So when you tighten the clamp it does not 'bite' into the hose. They are not cheap but are worth the price if you do not have to do the PITA job again. I replaced mine once with regular size fuel hose and was very :{ .

crabman

PS. Hope you have a good first aid kit handy!

 

[PaulG1]

Crabman,



Yes there is a West Marine nearby - good advice. I'll get some before yanking it off.



Is there a consensous on what the I. D. of the tube is?



This seams to be a rather lame design tucking the return lines away back there. After seeing this is a common failure I would say DC's design is patheticaly inadequate regarding reliability. My understanding is (from working with a fuel line system supplier that supplies to the big 3) that fuel system tubing and connections must meet a 15 year reliabilty spec. DC's design seams to fall considerably short of that. Any comments on this subject?

 

[EBottema]

Diesel fuel is harsh on rubber and when you pull the rubber out i bet it will say delco on it like mine did



GM product GRRR



Erik

 

[CarlJensen]

Fuel line is 3/8, return line is 5/16. Some have just replaced the whole run to the tank with marine grade hose rather than trying to rebuild the stock run. Removes a PITA factor!