fuel return lines - Chevy and GMC Duramax Diesel Forum
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Old 08-11-2010, 02:25 PM   eBay Motors  #1 (permalink)
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fuel return lines

how do i know whether to replace fuel return lines or just the metal funky looking two sided gaskets on them. im not sure how to diagnose which one is leaking. i will be replacing this weekend. and i would like to know a little about what to look for before i tear it down. diving in head first. also wold be nice to know where i can scoop these parts up or if theres a better brand above the others to use. anny help is much appreciated thank you
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Old 08-11-2010, 05:30 PM   eBay Motors  #2 (permalink)
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bump for a little help, i am doing this asap and dont want to have to do it agian thanks
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Old 08-12-2010, 07:23 PM   eBay Motors  #3 (permalink)
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Are you changing the injectors, or just trying to fix a leak?
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Old 08-12-2010, 07:47 PM   eBay Motors  #4 (permalink)
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trying to fix a leak
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Old 08-12-2010, 08:27 PM   eBay Motors  #5 (permalink)
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Have the return lines been messed with recently?

In most cases they do not just start leaking unless it was taken apart recently and not assembled correctly.

Best way to see where it is leaking would be to take the valve covers off and blow compressed air into the large fuel line that goes over the drivers side valve cover.

Then just look for a leak around the return line seals.

You can get the return line seals from Napa, and I also have a couple return lines for sale if you think that yours are bad.
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Old 08-13-2010, 05:25 AM   eBay Motors  #6 (permalink)
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Ok I have put injectors in about 5 trucks now and I always seem to never get the metal fuel lines to seal off they always start leaking after it gets hot. They are really tight to. What am I doing wrong? I always clean the rust of the tips of the lines with muratic acid to so they are nice and clean.
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Old 08-13-2010, 05:36 AM   eBay Motors  #7 (permalink)
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Could be your muratic acid is eating the mating surface "i am unsure if it can". I would use a more metal friendly cleaner



I have done a few sets and used this, and never had a leak once put back together.

PS: usually the rust is not even on the portion that would seal anyways. It is on the outer part that does not make contact, allowing moisture to rust it
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Old 08-13-2010, 06:27 AM   eBay Motors  #8 (permalink)
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my buddy that i bought it from said that he put a water pump on it about 3-4 months before i got it from him. most of the time when a water pump goes out the truck runs hot or at the least warm. so i am thinking that this is the cause of the leak.

"Best way to see where it is leaking would be to take the valve covers off and blow compressed air into the large fuel line that goes over the drivers side valve cover." this is probably the most helpful information yet now i just have to figure out which line and which way to blow. i was wondering if i could see a leak or just replace the stuff and hope i fixed it.
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Old 08-13-2010, 07:08 AM   eBay Motors  #9 (permalink)
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The fuel lines goes from the drivers side frame, up over the engine towards the drivers side. - You will have to take the lines apart when you remove the valve covers and you will see them then.
You will want to blow air in the large line which is the feed line for the engine. The small line is the return line to the tank.

You should be able to find a leak if you squirt oil over the return lines and look for bubbles or fuel leaking out, but if you do not find a leak then you could just replace the return lines and seals.

PS: Some guys have taken the valve covers off, and then hooked up enough stuff to be able to start the engine and look for leaks while the engine is running.

Good Luck!

Last edited by JoeSmith21; 08-13-2010 at 07:22 AM.
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Old 08-13-2010, 07:11 AM   eBay Motors  #10 (permalink)
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thanks for the info much appreciated.
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