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Go Back   SailNet Community > On Board > Gear & Maintenance > Engines > Diesel
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Diesel This is a forum dedicated to diesel engines and their applicable accessories.


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Old 07-20-2012
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4-107 Fuel Return Lines

The ones between the injectors. One was leaking, I changed them all. The old stuff was stiff plastic, press fit. The new stuff is rubbery, also press fit. It keeps popping off. I haven't found clamps that small. I tried zip ties, not good enough. I tried gasket sealer, not good enough. It seems to build pressure then pop off with a spray of diesel. I checked the other end, it's full of fuel. So it's not blocked. Anyone else had this problem?
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Old 09-09-2012
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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?
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Old 09-12-2012
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Re: 4-107 Fuel Return Lines

Try a motorcycle shop for small hose clamps.
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Old 09-14-2012
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Re: 4-107 Fuel Return Lines

Thank you both. I haven't been on SN much lately either. I'm about to try some reinforced hose with small screw clamps. I did try removing one section at a time to see if the flow was restricted, it seems not. Bella, I will PM you, thanks.
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