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Yeah there is no getting around it, Just get a 5/16 nut runner for the panel bolts and a socket and crescent for the larger lower line of bolts. Easy on, easy off.

I've tried it both ways, and I normally just put the spool of 1/8" line down where the oil fill battery would reside, and just pull to match the length of each section and cut in place. To each their own, whatever works.

All of the return lines, including #5, are all the same 3.5MM material (or the upgraded Gates). For the tees, I would chuck and put in new. I've bought them by the sack here: https://www.usplastic.com/catalog/item.aspx?itemid=104481 If you want a couple I will send them up your way. And yes...

Even if that piece of the hard line was opened slightly, it hits further restrictions down the pike with the Ts and final barb at the fuel tank.

Those are the primary fuel lines, that send fuel into the metering pumps, which pressurize the fuel injectors. At the end of the rigid line those 2 or 4 (depending on model you have) branch off of, is the start of the 'return' system.

Have you put a set of eyes on your return line, or are you basing this off seeing the soft lines that go to the metering pumps? I have not seen any crimps on a return fuel line in these sets, which is why I ask. If you are talking about the lines that go to the engine block (to the metering...

Ive used the Gates from O Reillys... its a little undersized, so it takes some definite elbow grease. But its readily in stock down the road, and should last quite long.

If only ALL were captive, our lives would be so much easier. Sadistic people I tell you... and howdy from Western MA :)

Oh I know the line (the rear sheet is off my set as we speak). I just didn't know if there was a barb, or if the nut 'captured' the hose, as it is not a high pressure line. Thanks

I don't know if that fitting has a barb. If it does, nothing more I need to do except strip the stock hose off of it and replace.

What should I do about the end of the return line, that goes into the tank? Can I get that fitting somewhere, that has a barb, that I can use hose clamps with? Or maybe a double male end barb, that I could cut the stock line an inch or two back from the OEM fitting, and install with dual duct...

Thanks for this info csheath. Was running my 802 before work this morning, and notice a nice pressurized leak coming out of one of the short fuel lines from the common rail, blasting diesel all over the right hand door. O-Reillys it is on the way home. Thanks again.