Burst fuel return line

Sindbad

Member
Apr 11, 2010
218
North Channel
Boat Info
340 Sundancer 2006
390 Sundancer 2005
44 Sundancer 2006
Engines
8.1L Horizons (2006)
8.1L HO (2005)
Cummins QSC 500 (44 DA, 2006)
Recently experienced this at beginning of 12 day Great Lakes trip. Stopped at first port (35 miles) noticed fuel smell, opened hatch, small swimming pool of diesel in bilge. Searched for leak and found burst return line, port engine. Had repaired then traveled to next port (30 miles). Upon entering harbor, wife said I was pumping "red stuff" overboard. Opened hatch, same issue, different burst location on return line. Fortunately, two diesel techs happened to be in the marina working on a large fishing boat; came aboard and investigated. Found that fuel return valve was closed (by someone at my local shop that regularly services my boat; shut off presumably done when filters were changed end of last season). Following day, I had both the feed and return lines replaced; continued on our trip with no further issue. As a result, I have decided I will do my own fuel, oil filters maintenance from now on! A costly lesson indeed for all CSR folks to note.
 
Sinbad,

Unfortunately you cannot trust your mechanic to do the job correctly. You have to go behind him and check their work. Too many times I've heard of work being performed and not done correctly.
 
Wow, What a head ache and I can imagine the mess. I helped a buddy find a leak in a failed fuel filter that painted his entire engine room red! It does seem wrong that you should have to double check a professional's work. The pros we hire charge for their expertise and part of the exurbanite price they charge is for the liability that they are exposed to when performing critical maintenance. I would hope that you would have a friendly conversation with your service provider to let him know of his oversite and give him a chance to at least chip in for some of the out of pocket expense you encountered. Had the hose not burst relieving the pressure who knows what damage would have been done to your fuel injection system. It begs to question why the first guy that fixed your burst hose did not determine a root cause though and open the return valve. There are some real idiots that call themselves mechanics out there. They should be required to wear a sign!
Carpe Diem
 
Wow, What a head ache and I can imagine the mess. I helped a buddy find a leak in a failed fuel filter that painted his entire engine room red! It does seem wrong that you should have to double check a professional's work. The pros we hire charge for their expertise and part of the exurbanite price they charge is for the liability that they are exposed to when performing critical maintenance. I would hope that you would have a friendly conversation with your service provider to let him know of his oversite and give him a chance to at least chip in for some of the out of pocket expense you encountered. Had the hose not burst relieving the pressure who knows what damage would have been done to your fuel injection system. It begs to question why the first guy that fixed your burst hose did not determine a root cause though and open the return valve. There are some real idiots that call themselves mechanics out there. They should be required to wear a sign!
Carpe Diem
Indeed......a lesson to not be forgotten; I will be having a conversation with the local shop.
 
I just dont trust anyone any more.... I do everything I can myself...it sucks and takes away time but at least its my fault. This site and a few others are invaluable to do it yourself
 
The first month of ownership 13 years ago, the survey mechanic had replaced all fluids and filters. I was out in the Sound and noticed the aft bilge pump light at the helm coming on, I go to the E.R. immediately and the CAT fuel filter mounted on the starboard engine had blown out the rubber seal. The cleanup was not a fun job...
 
Trying to understand why they closed the return valves to change filters???
 
I just dont trust anyone any more.... I do everything I can myself...it sucks and takes away time but at least its my fault. This site and a few others are invaluable to do it yourself
Absolutely agree.
 
Trying to understand why they closed the return valves to change filters???
Good question. As I understand, it is not necessary for changing Racors or on engine. The shop didn't have an answer.
 

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