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Old 03-29-2006
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fuel-return line.. .

can the engine, fuel-return line be plumbed into the fuel-fill hose and how can it be done?
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Old 03-29-2006
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Although I'm not a diesel specialist.. I think it is not a good thing.. as there is some positive pressure into the fuel-fill hose and I don't see how the fuel in excess could be evacuated??

Usually the fuel-return line go back into the reservoir..
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Old 03-29-2006
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You just want to get the excess output of the pump fed back into the tank. Make sure there is a good path back into the tank. The thing to keep in mind is that there is a larger flow than what you might expect. Make sure that at the junction, a strong squirt will flow smoothly back to the tank and not generate splashing in the fill line.
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Old 03-30-2006
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The issue here is you do not want any holes in that fuel fill line anywhere! They WILL leak. First comes diesel odor then eventually diesel.

If you must plumb things in this way. I would cut the fill line, install a metal T-fitting, and plumb the return line into the T. I would do this as low as possible in the line -- or better still attach the "T" directly to the tank inlet

This needs to be low in the line becasue almost all diesel istallations will specify that the return line run down from the engine to the tank. The sytem is not designed for any back pressure as a result of pumping "up." Clearly that can happen intermittently as a boat piches or rolls though.

Also be aware the return fuel stream is pretty significant and can generate foaming which could climb back up the fuel fill line depending on its diameter, and temperatures.
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Old 03-30-2006
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Thank you. I'll burn the fuel in the tank that is plumbed properly and pump the fuel to that tank... .. drill a fitting hole, tap it and plumb it in the right way. I just didn't want to go through all these steps. Later, fair winds.
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Old 03-31-2006
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Life is hard

Sigh. Why does it always seem that the hard way is the right way?
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