Engine/Transmission (1994 - 1998) Fuel Return Line Location Diagram, Anyone?

[Matt42]

I'm fixin' to crawl under my CTD and replace the fuel return line. It's not leaking, but it is seven years old in a climate that destroys rubber parts. Daytime driveway temperatures are now often below 100F, so it's safe to crawl underneath.



I've armed myself with three feet of 5/16 inch fuel hose and a sharp knife to cut it to length, plus tools and a dictionary of new cuss words.



I've searched the archives, but I can't find a diagram that shows the return line in relation to the other necessary doo-dads. Does anyone have such a diagram handy? And, based on your experience, does the Prime-Loc fuel filter relocation device I installed make the job easier or worse?



Thanks ahead of time.

 

[Bob4x4]

I don't have a diagram,but it is easy enough to find. At the top you will find it under the intake behind where the original fuel filter would be. 9/32 socket to loosen that clamp,split the hose with a razor blade so it will slide off easy. then from the bottom disconnect the line at the quick disconnect fitting. That way you don't have to try to reach the lower clamp. There are two clamps on the bell-housing that secure the hard line. Note the routing and direction you will have to move the line to get it free. It is not too tough,but you will be hugging that engine to reach everything.



Bob

 

[illflem]

You can see the hose here where it passes under the water temp sensor, passes behind the fuel filter then connects to the steel line a few inches forward of the filter.



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[Matt42]

Thanks

Thanks Bill & Bob.



I've printed a big copy of the diagram to carry in the glove box.



Bob: I always hug my Cummins, especially when I return from a road trip in the office's Chevy 6. 5! Its most spectacular breakdown was atop Lost Trail Pass, not far from Bill.

 

[Howard Durand]

Matt,

When I replaced mine, I removed the starter and disconnected the front drive line and worked from underneath. For me that was the easiest way to go. I have the Banks Twin Ram intake manifold which makes it more difficult to get to things from the top. Also, from underneath, you have pretty good visibility of both lines and the clamps.

Since you have the Prime Lok filter system it may be easier from underneath for you too.

I used a 1/4 inch drive socket with a universal joint and a couple of long extensions to reach the clamps.