Fuel Return Line: Service and Repair

NYLON FUEL LINES:

Nylon fuel lines are designed to perform the same function as steel or rubber fuel lines they replace. Nylon lines are constructed to withstand maximum fuel system pressure, exposure to fuel additives, and changes in temperature.
The fuel feed, return, and vapor lines are assembled as a harness. Retaining clips hold the lines together and provide a means for attaching the lines to the vehicle. Quick connect type fittings are used at the ends of the fuel feed/return lines and at the in-line fuel filter. Sections of the lines that are exposed to chafing, high temperature or vibration are protected with heat resistant rubber hose and/or coextruded conduit.
Nylon fuel lines are somewhat flexible and can be formed around gradual turns under the vehicle. However, if forced into sharp bends, nylon lines will kink and restrict fuel flow. Also, once exposed to fuel, nylon lines may become stiffer and are more likely to kink if bent too far. Some special care should be taken when working on a vehicle with nylon fuel lines:
WARNING: To reduce the risk of fire and personal injury when working on nylon fuel lines:
^ Always cover nylon fuel lines with a wet towel before using a torch near it. Also, never expose the vehicle to temperatures higher than 239°F for more than one hour, or more than 194° for any extended period.
^ Take care not to nick or scratch the nylon fuel lines. If damaged, they must be replaced.

QUICK-CONNECT FITTINGS:

Quick connect type fittings provide a simplified means of installing and connecting fuel system components. There are two types of quick-connect fittings, each is used at different locations in the fuel system. Each consists of a unique female socket and compatible male connector. O-rings, located inside the female socket, provide the fuel seal. Integral locking tabs or fingers hold the fittings together. The quick-connect fittings used at the fuel filter and other connections at the rear of the vehicle have hand releasable locking tabs. The fittings used at the engine fuel pipes have locking tabs that require a special tool to release.

FUEL LINE - ENGINE COMPARTMENT TO FUEL FILTER

NOTE: If nylon fuel feed or return lines become kinked, and cannot be straightened, they must be replaced. DO NOT attempt to repair sections of nylon fuel lines. If damaged, replace.

Engine Fuel Feed And Return Lines:

REMOVAL:

Tool required: J 37088-2 Fuel Line Separator Tool

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure, refer to MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELIEF.
3. Raise the vehicle on a hoist.
4. Disconnect the quick-connect fitting at the engine compartment fuel feed line.
a. Grasp both ends of one fuel line connection and twist 1/4 turn in each direction to loosen any dirt in the quick-connect fitting.

WARNING: Safety glasses must be worn when using compressed air, as flying dirt particles may cause eye injury.

b. Using compressed air, blow the dirt out from the quick-connect fittings.
c. Insert the J 37088-2 tool into the female connector, then push inward to release the male connector.
5. Disconnect the quick-connect fitting fitting at the fuel filter.
a. Grasp both ends of the fuel line connection and twist 1/4 turn in each direction to loosen any dirt in the quick-connect fitting. Repeat for the other fitting.

WARNING: Safety glasses must be worn when using compressed air, as flying dirt particles may cause eye injury.

b. Using compressed air, blow the dirt out from the quick-connect fittings.
c. Squeeze the plastic locking tabs of the male end connector of the fuel line, then pull the connection apart.
6. Clean and Inspect:
^ If it is necessary to remove dirt or burrs from the engine compartment fuel pipe, use emery cloth in a radial motion with the tube end to prevent damage to the O-ring sealing surface.
^ Using a clean shop towel, wipe off the male tube ends.
^ Inspect the connectors for dirt and burrs. Clean or replace components/assemblies as required.

INSTALLATION:

WARNING: To reduce the risk of fire and personal injury:
^ If the fuel filter is nicked, scratched or damaged during installation, it must be replaced.
^ If nylon fuel lines are nicked, scratched or damaged during installation, they must be replaced.
^ When installing new fuel lines, DO NOT hammer directly on the fuel harness body clips as it may damage the nylon lines resulting in a possible fuel leak.
^ Before connecting line fittings, always apply a few drops of clean engine oil to the male tube ends. This will ensure proper reconnection and prevent possible fuel leaks. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated).

1. Position the new fuel line in the proper location.
2. Remove the protective caps from the new fuel line.
3. Apply a few drops of clean engine oil to the male connector tube end.
4. Connect the quick-connect fitting at the fuel filter.
a. Push the connector together to cause the retaining tabs/fingers to snap into place.
b. Once installed, pull on both ends of the connection to make sure the connection is secure.
5. Repeat the connect procedure for the other end of the fuel line.
6. Lower the vehicle.
7. Tighten the fuel filler cap.
8. Connect the negative battery cable.
9. Turn the ignition switch to ON for two seconds, then turn the ignition switch to OFF for five seconds. Again turn it ON and check for fuel leaks.

FUEL LINES - FUEL LEVEL METER TO FUEL FILTER

NOTE: If nylon fuel feed or return lines become kinked, and cannot be straightened, they must be replaced. DO NOT attempt to repair sections of nylon fuel lines. If damaged, replace.

Fuel Pump/Sending Unit Installation (Convertible):

Rear Fuel Feed, Return And Vapor Lines & Filter (Convertible):

Fuel Filter (Coupe):

REMOVAL:

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure, refer to MAINTENANCE PROCEDURES/ FUEL SYSTEM PRESSURE RELIEF.
3. Raise the vehicle.
4. Disconnect the quick-connect fitting at the fuel level meter and the in-line fuel filter.
a. Grasp both ends of one fuel line connection and twist 1/4 turn in each direction to loosen any dirt in the quick-connect fitting.

WARNING: Safety glasses must be worn when using compressed air, as flying dirt particles may cause eye injury.

b. Using compressed air, blow the dirt out from the quick-connect fittings.
c. Squeeze the plastic tabs of the male end connector of the fuel feed line, then pull the connection apart.
d. Repeat for the other fitting.
5. Remove the fuel feed line routing retainers and fuel feed line.
^ Note the position of the fuel line for installation.

INSTALLATION:

WARNING: To reduce the risk of fire and personal injury:
^ If the fuel filter is nicked, scratched or damaged during installation, it must be replaced.
^ If nylon fuel lines are nicked, scratched or damaged during installation, they must be replaced.
^ When installing new fuel lines, DO NOT hammer directly on the fuel harness body clips as it may damage the nylon lines resulting in a possible fuel leak.
^ Before connecting line fittings, always apply a few drops of clean engine oil to the male tube ends. This will ensure proper reconnection and prevent possible fuel leaks. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated).

1. Position the new fuel line in the proper location as noted during disassembly, and connect the fuel line harness body clips.
2. Remove the protective caps from one end of the fuel line.
^ Leave the cap on the other end of the line to prevent dirt from entering.
3. Apply a few drops of clean engine oil to the male connector tube end.
4. Connect the quick-connect fitting at the fuel level meter assembly:
a. Push the connector together to cause the retaining tabs/fingers to snap into place.
b. Once installed, pull on both ends of the connection to make sure the connection is secure.
5. Repeat the connection procedure for the other end of the fuel line at the filter.
6. Lower the vehicle.
7. Tighten the fuel filler cap.
8. Connect the negative battery cable.
9. Turn the ignition switch to ON for two seconds, then turn it OFF for five seconds. Again turn it ON and check for fuel leaks.