Temporary fuel supply line fix - inexpensive and easy

[rdsoxx]

Based on the set-up of the fuel supply and return lines near the fuel tank, they are prone to rusting if you live in a road salt area. My lines were badly corroded, causing a leak in the supply line. I was losing prime and my truck was cranking way too long before it started. Anyway, GM sells replacement lines (both feed and return are one part number) but they are several hundred dollars. I didnt have that cash right now so here ya go:

My leak was at the quick connect connection between the flexible line from the fuel sending unit to the hard line, right above the return fuel cooler.

I jacked the bed up and removed the flexible line from fuel sending unit (this was the hardest part actually, PITA). The male end of the connection is exactly 0.500" OD. I cut my fuel supply hard line in an area along the frame that was not corroded. That line is 0.515" OD. I prepped the hard line with some emery cloth. I ran a 0.500" ID, 0.875" OD hose, compatible with diesel rated at 750 PSI between the male connection at the fuel sending unit to the supply hard line I cut. It is a nice tight fitting at both ends. I installed some high end hose clamps that apply equal pressure (they dont really make fuel injection clamps that big). Works quite well, no leaks, trucks starts right up.

[jc1843]

Good job-- I am sure that many are having that same problem due to the corrosion. The stock fuel system from the tank to the CP3 runs on negative pressure. So no reason to be concerned about the clamps.

[rdsoxx]

I was more concerned about vibration. I'll post some picks to make this a DIY.

[ieetgluu]

Im in the leaking fuel line boat. Got those pics? lol. Any chance I could just use rubber fuel line from tank to the quick connects at the engine(the ones removed for the diy injector cleaning)?

[huntman]

I ran rubber from my ad2 up to tne engine i couldn't undo it above tne fuel cooler.

[ieetgluu]

Im just wondering if a rubber feed line will collapse, as I dont have a lift pump yet

[jamiesgarage]

Originally Posted by ieetgluu

Im just wondering if a rubber feed line will collapse, as I dont have a lift pump yet

i always use plastic 3/8 airline & compression fittings (for airbrakes). its fuel resistant, wont rust and wont collapse. i use it in pickups and big rigs. never had a problem.

[rdsoxx]

The line I ran was pretty serious, 750 psi capable, so on the suction (supply line) no chance in hell it's collapsing. No photos on my iPad to share, I'm traveling.

[ieetgluu]

So what youre saying is, I can skip the $230 feed and return lines to/from the tank and use rubber fuel line? Why the hell didnt GM do that in the first place. Between the fuel lines, brake lines, rockers, cab corners and frames, these things have plenty of potential rust/rot issues already

[rdsoxx]

pretty much. look at your fuel filter - all rubber lines to and fro!

where in NH are you? i spend a good amount of time up there. in and around the marlow area.