Engine/Transmission (1994 - 1998) Relocating Fuel Return Line

[rrausch]

It's time to replace my return & supply lines, and I ordered the good marine USCG approved ones from Larry B. , but I want to relocate the return line so I don't have to snake it through it's little cave between the head & intake manifold.



So what is needed to relocate the Fuel Return line? I've seen Threads on doing it, but haven't had any luck with the search feature in getting the exact info on what if anything to change on the Injection Pump. Do I have to buy some sort of small fitting? Or just carefully point the steel part of the line in a different direction? Anybody know?

 

[Matt42]

Joe Donelly (I think) mentioned something about replacing the fuel return fitting. It uses a banjo bolt attaches to a 5/16 inch barb. My few local inquiries about what size banjo bolt would be needed (and what barb fitting to use) have resulted in blank stares.



I'd like to have the parts on hand before I disembowel.



On the other hand, I recently did the return line replacement thru the cave. the cuts and bruises are beginning to heal. Removing the dashboard for the heater core was actually easier.

 

[rrausch]

Matt, we have twin trucks. Mine is Emerald over Driftwood also! Personally I think that is the best paint combo I have ever seen!



Thanks for your input. I agree about having the right parts on hand before starting the job--saves a lot!

 

[Dieselnerd]

When I changed mine I just used a longer hose and routed it around the front of the fuel filter. Now the whole line is visible and the rubber is not against the hot engine. Several others have done the same thing.

 

[rrausch]

Dieselnerd, did you have to use any kind of special fitting, or did you just route it differently?

 

[PKemp]

Return Line Fitting

Ford chasis found in UPS trucks use the cummins 5. 9 engine with the p-7100 pump. The fuel ruturn line fitting is the banjo bolt type with the return pressure valve in it but it has a short nipple fitting to connect a ruber hose running up over the pump rather than behind it and the fuel filter. If you use the marine hose this should last forever since it would get the hose up and away from the heat from the block. I'll try to get the part number of the fitting for you. I did this on mine about 60k ago and its been fine ever since. But I didnt save the part number.

 

[JGheen]

How long do you guys think these stock supply and return lines actually last? How do you tell if the line is damaged or getting damaged since it is out of view behind the pump and filter? Is it easy to see when you remove the fule filter housing? I can't remember if I saw it when I changed out my filter a while back. I wanna say I have a complete hard line with no 5/16" hose piece, going from the overflow valve all the way to where it connects to the quick disconnect hose behind the filter housing, but others on here suggest that I have that small piece of 5/16".

 

[Dieselnerd]

rrausch, I did not use any special fitting. You may have to bend the metal line outward a bit. I don't remember for sure if I did or not but it's easy to re-route around the front of the fuel filter. On my old one, the part of the hose that was cracked and damaged was the part that was against the engine. The rest of the hose looked good.

 

[Matt42]

Re: Return Line Fitting

Originally posted by PKemp

Ford chasis found in UPS trucks use the cummins 5. 9 engine with the p-7100 pump. The fuel ruturn line fitting is the banjo bolt type with the return pressure valve in it but it has a short nipple fitting to connect a ruber hose running up over the pump rather than behind it and the fuel filter. If you use the marine hose this should last forever since it would get the hose up and away from the heat from the block. I'll try to get the part number of the fitting for you. I did this on mine about 60k ago and its been fine ever since. But I didnt save the part number.

Please, please, please: When you locate the part number, please post it. Thx. ,

 

[MLee]

Banjo bolt

Did this part come from a Cummins distributer? Odd that a ford chassis has a Cummings engine. usually its the PSD.

Marv.

 

[Cooker]

Re: Banjo bolt

Originally posted by MLee

Did this part come from a Cummins distributer? Odd that a ford chassis has a Cummings engine. usually its the PSD.

Marv.

Ford hase been putting a Cummins in a 650 series for quite some time.