Attention: TDR Forum Junkies 
Matt42
TDR MEMBER
I last replaced the fuel return line from the P7100 injector pump in my 1996 CTD in about 2004. I think. The pages in my log book are dried and crumbling. I installed marine grade hose at the time. But the heat and the 10% humidity take their toll on everything.
At least I think it's the return hose that's leaking. It only leaks when the truck is running. If I start the truck the next day, it starts up OK. If I leave it for a week, it has to crank for a while. When it leaks, there's a visible dribble that's underneath the intake manifold area, more or less behind the fuel filter boss. The annotated image just below (stolen from Joe G.) shows the approximate location of the leak.
My hands and arms are way to big to get in there, but I obviously did--somehow--12 years ago. I looked using an inspection mirror and an LED flashlight. I could see what appeared to be the marine 5/16 inch hose and clamp. But it is up higher than indicated in the diagram. (Joe G.'s example is from a different year.)
So a couple of questions.
(1) Does my description seem right for a relapse of the leaky return line hose connection?
(2) There is a whole lot of stuff in the way, including a Pac-Brake line added in the interim. What do I need to move, or remove, to get access without excessive cuts and bruises?
(3) Is there some sort of right angle fitting, banjo bolt, barb connector, or whatever that I can install into the back of the injector pump that will allow me reroute the return hose downward?
Many thanks.
At least I think it's the return hose that's leaking. It only leaks when the truck is running. If I start the truck the next day, it starts up OK. If I leave it for a week, it has to crank for a while. When it leaks, there's a visible dribble that's underneath the intake manifold area, more or less behind the fuel filter boss. The annotated image just below (stolen from Joe G.) shows the approximate location of the leak.
My hands and arms are way to big to get in there, but I obviously did--somehow--12 years ago. I looked using an inspection mirror and an LED flashlight. I could see what appeared to be the marine 5/16 inch hose and clamp. But it is up higher than indicated in the diagram. (Joe G.'s example is from a different year.)
So a couple of questions.
(1) Does my description seem right for a relapse of the leaky return line hose connection?
(2) There is a whole lot of stuff in the way, including a Pac-Brake line added in the interim. What do I need to move, or remove, to get access without excessive cuts and bruises?
(3) Is there some sort of right angle fitting, banjo bolt, barb connector, or whatever that I can install into the back of the injector pump that will allow me reroute the return hose downward?
Many thanks.
