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Thread: MEP-802/803 fuel return improvements

  1. #41
    4 Star General Steel Soldiers Vendor m-35tom's Avatar
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    I know there has been a lot of discussion about 3.5mm being the right size but 4.0mm is readily available and about 50 cents per foot and is just .020 thousandths larger so it goes on just as tight.
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    As long as it works, it works!

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    Howdy,
    FUEL RETURN LINE = very low pressure
    To each there own.
    I used the braided original style line. With keeping it filled with diesel #2 and not using JP8, it will last longer than the military fuel type use.

    The MEP-8xx series of generator all use diesel fuel return lines. After sometimes sitting with no fuel, or heat cold, no-use etc... they start to fail. The main issue is the lines start weeping fuel.

    NSN 4720-01-483-6467 part N20353.5 HOSE,NONMETALLIC
    Name Value
    CROSS-SECTIONAL SHAPE STYLE ROUND
    INSIDE DIAMETER 3.5 MILLIMETERS NOMINAL
    LAYER COMPOSITION AND LOCATION OUTER LAYER BRAIDED COTTON CORD
    INSIDE SURFACE CONDITION SMOOTH
    SPECIAL FEATURES COMES IN A 20 METER ROLL (66 FT.)
    MATERIAL RUBBER BUTADIENE-ACRYLONITRILE CLASS NBR TUBE
    MEDIA FOR WHICH DESIGNED FUEL/OIL, HYDROCARBON SINGLE RESPONSE AND WATER SINGLE RESPONSE AND AIR SINGLE RESPONSE



    The fuel return line is 3.5mm ID. As you can see by the above posting the details of this line. Some have used other sizes and hose clamps. But purchasing the correct 3.5mm ID fuel hose makes it stay tight on all the hose barbs without issue.

    It is a 3.5mm fuel hose made by CRP CONTITECH. This is a roll which is 5 meters long which will give you enough to replace all your lines and have some in reserve. You can search for below

    CRP N203535-5 CONTITECH Diesel Hose
    Contitech 3_5mm fuel hose.jpg

    Or
    Gates Safety Stripe II - 1/8 Inch Hose Part 27000 which is 3.2mm ID
    Gates Safety Stripe II hose.jpg
    ~~Later Mike

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  6. #44
    4 Star General Light in the Dark's Avatar
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    Thanks for this info csheath. Was running my 802 before work this morning, and notice a nice pressurized leak coming out of one of the short fuel lines from the common rail, blasting diesel all over the right hand door. O-Reillys it is on the way home. Thanks again.

  7. #45
    4 Star General Light in the Dark's Avatar
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    What should I do about the end of the return line, that goes into the tank? Can I get that fitting somewhere, that has a barb, that I can use hose clamps with? Or maybe a double male end barb, that I could cut the stock line an inch or two back from the OEM fitting, and install with dual duct clamps?

  8. #46
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    Dosnt the fuel return at the tank just push on a hose barb? That small 3.5mm of return line a hose clamp may not be the thing to use. You can use SS wire. I used small zip ties.

    Also i have ordered the contitech hose daybreak posted from amazon. It was enough to do two 802a, cant remember the exact length.
    Heres the amazon link.
    https://www.amazon.com/CRP-N203535-5...35-5+CONTITECH
    Last edited by Bmxenbrett; 11-21-2017 at 14:39.

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  10. #47
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    I don't know if that fitting has a barb. If it does, nothing more I need to do except strip the stock hose off of it and replace.

  11. #48
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    Yes just a brass hose barb. You can see it prety good in this pic. Its the smaller hose next to the red wire on the right side.
    https://www.google.com/search?q=mep8...hxhW51PRz4MNM:

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    Oh I know the line (the rear sheet is off my set as we speak). I just didn't know if there was a barb, or if the nut 'captured' the hose, as it is not a high pressure line. Thanks

  14. #50
    2 Star Admiral Daybreak's Avatar
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    Howdy,
    Yes, the 3.5mm stuff is what is factory. So, it goes right on top the barbs and stays on. No need for any clamping on the fuel return lines.
    ~~Later Mike

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