Engine/Transmission (1994 - 1998) Return Fuel Line Leak??? or something else????

[Jack fr MO]

Several years ago I replaced the fuel return hose, because it was leaking. The problem it caused was that when it sat for several days, it would start, but then die and it would take a lot of cranking to pump the fuel back to the injectors. At that time, I replaced both the metal line from the over flow valve to the fuel hose, problem solved. The problem has returned, before I start removing things, to get to that hose, is there something else more easily replaced that could be causing the problem? Thanks for any input....:--)

 

[gcorron]

Jack, it is a nuisance, but I didn't remove anything to replace the return line.

Does put you in an uncomfortable position, and you can greatly benefit from a service mirror, but basically have to feel your way through the connection towards the front of the engine, but a couple hose clamps, something to stand on, and two feet of fuel line should do it.

I have replaced the overflow valve for causing the same problem, did you replace it yet?

Good luck,

George

 

[LHastings]

I had the same problem. It turned out to be the fuel heater sucking air around the terminals , so I removed the heater problem solved.

 

[surfbeetle]

This is a common issue in the 12 valves. The rubber fuel lines by the bellhousing are prone to cracking and losing the fuel system prime. There are different types of fuel hose such as marine grade hose that are better than others but ultimately will end up cracking over time. You'll look at the hose and think that it's fine but it's not because of air leaks. Of course, the fuel heater can also leak and suck air as well but I have done the fuel lines many times over the last 19 years with my truck.

 

[GAmes]

http://www.cumminsforum.com/forum/94-98-engine/58777-joe-gs-fuel-system-writeup.html

 

[LandShark]

Had a similar problem a couple of years ago. Ended up replacing all the fuel lines with marine rubber lines, and bypassing the pre-filter and heater. Also added a NAPA diesel pre-filter to the feed line. I did a write up on this site if you want to search for it. As I recall I eliminated about a dozen possible leak points by doing this. Never did find out where the air was coming into the fuel system, but it was fixed.

 

[DRFriend]

Agree with above. Replacing all of my fuel lines was the best thing I ever did. I put in a draw straw I, got Larry B's kit for the marine feed and return lines, then replaced everything between the lift pump and the injection pump with a kit from Vulcan. Bypassed the fuel heater/screen, and added an inline pre filter along the frame.