Join Date: Jan 2007
Location: Penobscot Bay Maine
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Re: 4-107 Fuel Return Lines
Sorry for not replying to your post sooner (I haven't been on SailNet much this summer). The "right stuff" for these injector return lines is .190" by .250" by .030" Nylon -12 semi-rigid black tubing. I renewed mine a year or two ago, and have the remains of a 10 foot coil still in the bag down cellar. If you want to PM me your mailing address, I'll send you a piece long enough to re-do yours (no charge - just pay a favor forward for someone else).
This material is push-on, and theoretically does not require any "hose clamps". Mine is fine between the injectors, but does leak a little at the one connection on top of the fuel filter assembly. I couldn't find hose clamps small enough either, and tried using SS tie wire - slowed the leak but didn't stop it.
If you find any miniature hose clamps, please let us all know!
If the new tubing "blows off" - you may have blockage somewhere in your fuel return system. There is a small ball check valve inside the banjo bolt assembly at the top of the fuel filter - maybe plugged?