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Old 12-31-2012, 12:02 AM   #1
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High fuel pressure

So i have had a fuel problem with my 2.5l. checked fuel pressure and it was high at 70psi at idle. so i disconnected the return and started with the gauge, and it dropped back to normal pressure, around 35psi. So obviously theres a blockage in the return line going back to the tank. i did find a couple things online saying the return gets pinched between the body and subframe right by the tank. dropped the tank to access the hose going into the fuel pump housing. i was just wondering if theres anything else thats common that i should look for. i pulled both feed and return hoses off and they are clear and not clogged. any info would be awsome. hoping to get the tank back up and it run normal tomorrow.

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Old 01-02-2013, 11:41 PM   #2
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so the story is i just bought this truck and it ran like crap. so it's always had high fuel pressure. well, i found out the reason for the high fuel pressure and after replacing both return and feed hoses going to the fuel pump/sending unit assembly, and messing with it for an hour or so, i decided to pull the sending unit assembly and found the "straw" for the return goes all the way to the bottom of the tank. well, i guess the bottom of the tank is bowed in a little bit from previous owner wheeling it, or what not, causing the return to be blocked from the tank. after some slight cutting of the return "straw", fuel pressure is normal.

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Old 01-03-2013, 08:28 AM   #3
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Just suffered the same issue. The return is very close to the bottom of the pump well. A well placed bump to the tank pushed the return line against the bottom of the tank, restricting the return. I fixed the skid plate and used a small tubing cutter to remove the bottom 1/2" of the return line. I also used a v-shaped file to cross cut some notches in the outlet in case it happens again. The return is still below the pickup screen, but now only by 1/8". Dropped in a new Bosch pump while I had the tank down, I have crappy luck and the original pump would have died soon there after. LOL!
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Old 01-03-2013, 08:48 AM   #4
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Haha yea.. What a terrible design.. After I figured it out I almost scrapped the whole deal and went fuel cell... If it happens again, that's what I'm doing
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