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Fuel return line

7.4K views 23 replies 6 participants last post by  Big-n-Broke-YJ  
#1 ·
I have some kind of fuel line completely broken into two under my jeep. It constantly sprays gasoline out when I'm driving and drips out for about 5 minutes after I shut the engine off. When I downshift or suddenly let off the gas it sounds like a jake brake on a semi coming from under the jeep (what I suspect is air being sucked into the same line). The jeep runs fine so I know its not my fuel line so I suspect it is some kind of fuel return line.

Anybody have any ideas on what it is and how hard it is to fix myself?

Thanks in advance,
Russ
 
#2 ·
If it's the line with your fuel filter, it's the pressurized side of the fuel system, if it's the other line it is the return line. If you test the fuel pressure at the fuel rail with a pressure tester it should read about 32 psi with the vacuum hoses all attatched, if it does indeed read this then you know your pressurized line isnt line damaged (or clogged...) It should be an easy fix, is it broken on a rubber hose or at a metal part of the line?
 
#4 ·
fuel filter?

Ok I looked around underneath and it seems the leak is coming from the vicinity of the fuel filter. Will the fuel rail pressure check show me anything there? I will have to wait to get some garage time at the local shop to check the pressure.

It seems I have 3 lines going Into the tank. 2 larger ones that look relatively new, and one smaller one that is pretty much all rust.

I noticed that around the same time I began leaking fuel that it is now taking me 4-5 times as long to start the engine too.

Thanks for the quick reply and thanks again for the advice.

Russ
 
#6 ·
Berb_15 said:
If it's the line with your fuel filter, it's the pressurized side of the fuel system, if it's the other line it is the return line. If you test the fuel pressure at the fuel rail with a pressure tester it should read about 32 psi with the vacuum hoses all attatched, if it does indeed read this then you know your pressurized line isnt line damaged (or clogged...) It should be an easy fix, is it broken on a rubber hose or at a metal part of the line?
What was broken was actually my E-brake line. The leak must be a leaky fitting or just a corroded tube. I see three lines going to the tank, 2 newer large ones and one really rusty smaller one. The gas is leaking in the near vicinity of the fuel filter.
 
#8 ·
atomicmoose said:
My bet is that you can't start the jeep due to lack of fuel pressure. Get that line replaced ASAP.
Should I start by just replacing the fuel filter (seems like a $20 fix and easy enough to do) or are you suggesting I buy all new fuel lines? I checked Quadratec and they don't have preformed fuel lines for the YJ and the ones they do have (CJ) are about $110 for all new lines.
 
#9 · (Edited)
Here are my fuel lines going from the fuel filter into the wheel well.
Image


This is the vicinity from which the leak is coming from. The whole lower area gets soaked with gasoline.
Image


This is the view of the outlet fitting on the fuel filter.
Image


This is the view of the inlet fitting for my fuel filter
Image


Here is where I originally thought the leak was from, but after tracing it out turns out its for my E-brake which is currently out of service (for obvious reasons).
Image
 
#10 ·
norsoulnet said:
Here are my fuel lines going from the fuel filter into the wheel well.
Image


This is the vicinity from which the leak is coming from. The whole lower area gets soaked with gasoline.
Image


This is the view of the outlet fitting on the fuel filter.
Image


This is the view of the inlet fitting for my fuel filter
Image


Here is where I originally thought the leak was from, but after tracing it out turns out its for my E-brake which is currently out of service (for obvious reasons).
Image
Click free......

Those are the blurriest pics ever... :thumbdown:
 
#11 ·
atomicmoose said:
Click free......

Those are the blurriest pics ever... :thumbdown:
Yeah I suck at taking pics. As you can see however there are no clear breaks visible in the lines. Which is why I think it might be the fittings on either end of the fuel filter.

I don't think the camera I'm using is meant for things inches away from it.
 
#12 ·
norsoulnet said:
Ok I looked around underneath and it seems the leak is coming from the vicinity of the fuel filter. Will the fuel rail pressure check show me anything there? I will have to wait to get some garage time at the local shop to check the pressure.

It seems I have 3 lines going Into the tank. 2 larger ones that look relatively new, and one smaller one that is pretty much all rust.

I noticed that around the same time I began leaking fuel that it is now taking me 4-5 times as long to start the engine too.

Thanks for the quick reply and thanks again for the advice.

Russ
If it takes longer to start it is definatly probobly your pressurised line and your pressure probobly goes to 0 each time you turn your motor off. The only way to locate the hole would probobly be to see it leaking in action.... If you do in fact have to replace the metal line pm me I just did a swap and have an extra pair of lines I'm not using... If your rubber lines on either side of the fuel filter are dry rotted it would probobly be a good idea to replace them anyways. The smaller line you see coming from the tank is a vent line that travels up to your cabon canister(i think thats what its called?) so there's no fuel traveling through it. I'd start by replacing those rubber pieces and if you havent replaced the filter in a while it wouldnt hurt. If that doesnt fix the problem it may be a metal line. Keep us updated...
 
#14 ·
#15 ·
Berb_15 said:
If it takes longer to start it is definatly probobly your pressurised line and your pressure probobly goes to 0 each time you turn your motor off. The only way to locate the hole would probobly be to see it leaking in action.... If you do in fact have to replace the metal line pm me I just did a swap and have an extra pair of lines I'm not using... If your rubber lines on either side of the fuel filter are dry rotted it would probobly be a good idea to replace them anyways. The smaller line you see coming from the tank is a vent line that travels up to your cabon canister(i think thats what its called?) so there's no fuel traveling through it. I'd start by replacing those rubber pieces and if you havent replaced the filter in a while it wouldnt hurt. If that doesnt fix the problem it may be a metal line. Keep us updated...
As you can see I have a small undercarriage rust problem :) Damn Ohio salted roads. The two larger lines look fine without any visible outer corrosion, its just that one small vent line that looks like its all rust through and through.
 
#16 ·
go to the local parts store.... a filter from advance auto is about $9... buy some 3/8" fuel injection hose and 4 fuel injection hose clamps... they are smooth instead of slotted like a normal hose clamp which will cut into the rubber fuel line.

replace the filter and the short 3/8" rubber lines that connect the filter to the hardline.

it looks like the leak is coming from the 90 degree rubber bent fuel line.... those are a dealer only option but if you take your time and bend the rubber fuel line with enough of a radius, it won't kink and block fuel flow... just be patient.

definatly fix that before you burn down your jeep and possibly yourself....

-Erik
 
#17 ·
Yea I hear you on the salty roads thing... but to be honest those two sites only say fuel filter, Im not sure what to tell you. I would assume they woulcnt come with those rubber pieces. The best thing to do would be to call and ask, and if they dont they might be able to find them for you.
 
#18 ·
the filter does NOT come with the rubber hose on each end.

the 90 degree rubber line is a dealer only piece that costs about $25 if i remember right...

you can make one from 3/8" fuel line as i suggested in my previous post.

good luck
 
#19 ·
Big-n-Broke-YJ said:
the filter does NOT come with the rubber hose on each end.

the 90 degree rubber line is a dealer only piece that costs about $25 if i remember right...

you can make one from 3/8" fuel line as i suggested in my previous post.

good luck
ok I'll give it a shot. Its gonna be a few days though. Thanks.

Russ
 
#20 ·
I just went through this, what a pain in the A**!!!!

Here is what I found, and how I fixed it;

Jeep, for some unknown reason, put 3/8 nipples on the feed and return lines at the tank (pump), then use soft lines through the bulkhead in the frame afterwhich they connect to 1/4 hard lines (???????) that snake around the shock mount where the feed (hi-pressure) line uses another 1/4 to 3/8 soft line to connect to the fuel filter.

Well after almost choking the Jeep parts guy when he told me the price of those dealer only soft lines (over $150 for all of them!) I devised a plan!

First I dropped the tank to remove ALL of the old soft lines, AND the 1/4" hard line that snakes around the shock mount.

Next I cut 2 sections of 3/8" staight bulk hard line 12" long to insert through the bulkhead.

Lastly I connected all the pieces with new bulk hi-pressure 3/8" softline!

DONE....now the fuel system is 3/8" all the way through with no "special" lines!
 
#21 ·
the 1/4" hardline you speak of is 1/4" ID and the 3/8" fuel injection hose from your local parts store will go over that hardline just like stock did....
 
#22 ·
3/8" fuel injection hose from your local parts store will go over that hardline just like stock did....
You are right, it most certainly did, but I could never get the hose clamp tight enough to stop from leaking. Thats why I just eliminated it. I absolutely could not justify spending what the dealer wanted for some crappy pieces of rubber.
 
#24 ·
you could use another type of filter but there is no reason to.

a replacement filter for your jeep is about $8 or $9

a foot of 3/8" fuel injection hose is about $4.50

4 fuel injection hose clamps will cost you another $4

so for less than $20 you can fix your problem. Why complicate things?