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Leaky fuel return lines on the 803

dschoolxlt

New member
5
8
3
Location
Youngstown, Ohio
Hello All,

I have the 803. I’ve replaced the fuel return lines a few times with the standard issue cloth covered line. For some reason, I keep getting leaks on injector #3. The line either works it’s way off the injector, or separates at the tee. I tried a low tech solution of using a zip tie for a clamp, that ultimately keeps the line in-place, but it has a drip

I noticed it after running a load test. It appears the constant fuel leak over time dropped and ran toward the front of the engine toward the water pump plate. I ended up having a coolant leak between the plate and block. I replaced the pump & all gaskets, ended up using black oil resistant RTV with the gaskets in the hope that it will semi prevent it in the future. I have to assume the diesel fuel is what lead to the other gasket failing over time.

anyone else seen this?

32052FA4-8C78-4E62-979B-295F6FD0BA09.jpeg
 

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dschoolxlt

New member
5
8
3
Location
Youngstown, Ohio
Try this for line instead: https://www.oreillyauto.com/detail/...h-i-d-nitrile-rubber-nbr-fuel-hose/gatr/27000

Secure all of the T ends with small zip ties as you have done before and reinstall. It will take a bit of grease to possibly aid in sliding it all together, but it shouldn't leak again.
That’s a good idea! Thanks, I’ll keep it in mind.

I ended up pulling the cover off the fuel tank starting there to see if return fuel was making it back to the tank. It barely had any at all, so I pulled all the lines off and inspecting all the lines and tees again, thinking I had a clogged hose or tee. It ended up that the brass tee on the 3rd injector was not drilled all the way through. So essentially the pressure/fuel buildup from injectors 1-3 was pushing the hose off. I ran a drill thru the tee crosswise, put it all back together and verified I had fuel at the return.
So it looks like it solved it. It’s had a perpetual fuel leak on the return lines since I got the set. Even after changing all the lines.
 
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