I'm talking about the rubber ones from the tops of the injectors back to the union and the tank.

This all started a few weeks ago, I discovered a rodent nest on top of the intake/valve cover. Seems the critters like to use the woven covering of the fuel return lines in their nests. Cleaned it up, only to discover a leak at #4 return a few days later, with some signs that the rodents were still paying visits. On closer inspection, the leaky lines were ones where the rodents had chewed the fabric covering off the ends. Occasionally some tooth marks in the rubber, but not usually. The rubber hose splits right where it goes over a nipple on the return fittings.

So I have replaced about half of these rubber hoses, and given them all a coat of hot pepper (which does seem to be working in keeping the rodents away). However I am still getting a split hose end every week or so. So far on the older segments that I have not replaced yet. None of this hose was that old, got replaced with new hose ~ 1 year ago when I put in a Chevy return line kit. And even the split rubber seems fine, flexible and all. So it isn't aging rubber causing this.

I am curious if anyone has seen this problem before (return line hose splitting). And what causes it. I suspect the rodents, but perhaps there is another cause, like clogged return line to the tank or something.

Anyone know how much pressure is safe to put on the return line to check for flow back to the tank?

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2006 KJ CRD