Engine/Transmission (1998.5 - 2002) Fuel Leak in Return Line from VP44

[KBrennan]

I started to notice a diesel smell every time I would drive mote that 20 miles. I crawled under the truck and found the return line from the VP44 was leaking. It has one of those quick connects that goes into what looks like a thin polly line and then attaches to the stainless steel line that goes back to the tank. At the point that it mates with the SS line it looks like it was heat shrunk onto the the line. Do I have to replace the entire run or is there a way to replace the polly line only? One other thing, the polly line is covered with regular rubber fuel line. I figured that was done to protect the polly line.

 

[KBrennan]

No one has any ideas?

 

[JKreiss]

Hey there,



I had the same exact thing on my 99'. It caused a hard start condition when parked uphill which was fun diagnosing. Anyhow what I did was eliminate the quick disconnect from the return hard line at the rear of the block and took it all the way down to the heat shrunk section. I had to use a razor to take it down to the SS line. I then just replace it old school like with some rubber diesel fuel line and some hose clamps. It worked great and never had another issue. Remember the quick connects are to save time on the assembly line, not because it's the best way to do something. Hope that helps.

 

[KBrennan]

Hey there,



I had the same exact thing on my 99'. It caused a hard start condition when parked uphill which was fun diagnosing. Anyhow what I did was eliminate the quick disconnect from the return hard line at the rear of the block and took it all the way down to the heat shrunk section. I had to use a razor to take it down to the SS line. I then just replace it old school like with some rubber diesel fuel line and some hose clamps. It worked great and never had another issue. Remember the quick connects are to save time on the assembly line, not because it's the best way to do something. Hope that helps.

Would you by chance have a picture of what you did? I think I follow but a pic is worth a thousand words. Thanks

 

[JKreiss]

I sold the truck about 4-5 months ago. I can pull a picture out of the service manual but it won't be until tonight. Basically where the quick connect plugs in, is a hard line. Where it ends is a hard line, all you gotta do is connect the two points with a rubber fuel line. I was hesitant at first because it sounded like it was too simple but it worked out great.

 

[grimesja]

Troubleshoot that line carefully, I had what I thought was the same issue. I changed the line from the back of the block and the return line from the pump and elimated the quick disconnect. I still had a leak. I found out one of the injector lines was cracked and the fuel was leaking onto the line and following the path.



Just food for thought. John

 

[KBrennan]

Troubleshoot that line carefully, I had what I thought was the same issue. I changed the line from the back of the block and the return line from the pump and elimated the quick disconnect. I still had a leak. I found out one of the injector lines was cracked and the fuel was leaking onto the line and following the path.



Just food for thought. John

Thanks, I will take a closer look.

 

[GReed]

I had a leak in the return line on my 2002. I replaced the plastic clip in the quick disconnect and that cured the leak. You can get the clips at about any auto parts store. The return line is 5/16.