Fuel is used to cool and lubricate the fuel injectors and the fuel injection pump. The fuel return system is designed to return this fuel to the fuel tank. If the high side fuel pressure becomes excessive, the fuel rail pressure relief valve releases the fuel into the fuel return system . The return fuel travels through the fuel cooler to the fuel tank.

Bent or pinched fuel return lines may cause an external fuel leak or engine performance concerns.

Special Tools Required

J 44581 Fuel Line Disconnect Tool

Inspect the fuel return hoses and lines on the engine and chassis for any external fuel leaks.

Important: DO NOT apply more than the specified air pressure to the return line.

1. Disconnect the fuel return line at the engine. Refer to Metal Collar Quick Connect Fitting Service .
2. Remove the fuel filler cap.
3. Apply 1 psi of pressure air into the fuel return at the engine. Air flow should be detected at filler tube.
4. If air flow was not detected at the filler tube, disconnect the fuel return line at the fuel sender and apply 1 psi of air pressure into the fuel return line at the engine.

⇒	If air flow was present, replace the fuel sender assembly.

⇒	If no air flow was present, inspect for a restricted or a damaged fuel return line. Repair or replace the fuel return line.

Perform the Diagnostic Repair Verification after completing the diagnostic procedure.

Fuel Sender Assembly Replacement