Fuel return hose

[RVB90Ranger]

Here is a good one, 2.9L 1990 Ranger with leaking quick disconnect at the injector manifold where it connects to the fuel pressure regulator. This thing has more than a leak, more like a stream. Dealer says the hose is discontinued. No parts house carries the hose and a hose manufacturer in Fort Worth says they can’t get the connector to even make me one. My mechanic warns not to rig something because of the pressure generated on this return line. My only option…looks like a wrecking yard for another 18 year old hose and cross my fingers. This is really hard to believe…my truck is a cherry, 181K but runs and looks great. Ford part number is F0TZ9J338M. Anyone know a source or happen to have one of these laying around?

 

[MAKG]

I'd do the junkyard thing.

However, there isn't very much pressure in the return hose. It's AFTER the regulator. And even aftermarket regulators often come with barbs and hose clamps to connect them.

If there IS a lot of pressure in the return line, something is blocked. In addition to potential fuel leaks, this will make the engine run poorly due to excessive injector pressure.

And FYI, you can change O-rings in those quick connects. Which may be the cheapest and most reliable repair.

 

[High Desert Ranger]

Is the nylon line leaking or the disconnect itself?

Dorman makes replacement lines and I think they also do replace disconnects.

 

[RVB90Ranger]

This connector is at the regulator and has an internal seal. The connector on the other end is the more common one with o-rings. I may be mistaken if this is the return or feed. There is pressure on this fitting even with the truck off. I could push and pull on the hose prior to disconnecting it and could hear the pressure release. Truck runs good and milage is good for this engine so I don't suspect a blockge. I need a real shop manual instead of this aftermarket junk to know for sure.

 

[MAKG]

The RETURN line connects to the regulator. It should NEVER be under pressure with the vehicle turned off.

Why do you not suspect a blockage? I don't see how everything in that post can be correct simultaneously; SOMEthing has to give. If not the blockage, something else.

Which means, your fitting is leaking because the fuel has nowhere else to go once the engine is off. Though I'm more than a little surprised you didn't rupture the regulator first.

 

[WildSide]

MAKG is totaly correct! You better repair the blockage and I bet your leaking conector may solve itself.

 

[RVB90Ranger]

Yes, makes sense. I'll investigate the return line. This problem started out small and would just drip for a few minutes when I started the engine. I pushed the connector to reseat it and it was good for a while until it started dribbling a constant stream and I had to quit driving it. If that return line is supposed to be nothing more than a zero pressure way for gas to return to the tank then there must be a problem "down stream".

 

[WildSide]

First thing to do is trace the line and look for damage such as a pinch, then disconect at the tank and check flow.If all is well with the line focus on the tank sending unit.

BTW check conections for pitting and worn O rings.

 

[RVB90Ranger]

Fixed it

Well everything tested out fine so it was the quick disconnect at the regulator after all. I cut off the leaking quick disconnect and used a barbed connector to replace it with some new injector hose. Replaced the old regulator with a NAPA after market with a barbed connector clamped the heck out of everything and it's running fine with no leaks after two weeks. I hated to rig it this way but apparently it's the only way to fix this rare problem.

 

[grnrngr]

I had to go with the junkyard option...when I was putting my "new" motor back together, made the (dumb) mistake of trying to pick up the inductor by the fuel line.... snapped that fitting right off. I was fortunate to find one in almost new shape at the yard...