Fuel Return Line: Service and Repair

Supply And Return Line Replacement:

TOOLS REQUIRED
J 37088-A, Fuel Line Separator Tool Set.

NOTICE:
^ If nylon fuel feed or return pipes becomes kinked, and cannot be straightened, they must be replaced.
^ Do Not attempt to repair sections of nylon fuel pipes. If damaged, replace.

REMOVE OR DISCONNECT
1. Negative battery cable.
2. Relieve fuel system pressure. Refer to Fuel Delivery / Service and Repair.
3. Quick-connect fittings at fuel rail in engine compartment.
4. Fuel feed and return pipe retaining clip at brake booster.
5. Raise vehicle.
6. Quick-connect fittings at fuel filter.
7. Lower fuel tank shield attaching screws and lower fuel tank shields.
8. Fuel feed, return, and EVAP pipe underbody retainer.
9. Quick-connect fittings at fuel sender assembly.
10. Fuel feed and return pipe retaining clips and fuel feed and return pipes.
^ Note position of fuel pipes for installation.

INSTALL OR CONNECT
WARNING: To Reduce the Risk of Fire and Personal Injury:

^ If nylon fuel pipes are nicked, scratched or damaged during installation, they must be replaced.
^ When installing new fuel pipes, Do NOT hammer directly on the fuel harness body clips as this may damage the nylon pipes resulting in a possible fuel leak.


1. Lower vehicle.
2. Rear ends of fuel feed and return pipes into top forward frame hole.
3. Raise vehicle.
4. Route pipes in same position as noted during disassembly.
5. Quick-connect fittings at fuel sender assembly.
6. Fuel feed, return, and EVAP pipe underbody retainer.
7. Lower fuel tank shields and tank shield attaching screws.

Tighten
Lower fuel tank shield screws to 1 Nm (9 lb in.).

8. Quick-connect fittings at fuel filter.
9. Close all retaining clips.
10. Lower vehicle.
11. Fuel feed and return pipe retaining clip at brake booster.
12. Quick-connect fittings at fuel rail in engine compartment.
13. Negative battery cable.

INSPECT
^ Turn ignition switch to "ON" position for two seconds, then turn to "OFF" for ten seconds. Again turn to "ON" position and check for fuel leaks.