Fuel Return Line: Service and Repair

Fuel Line Quick Connect Fitting:

DISASSEMBLY

NOTE: The O-rings used in the quick-connect fittings are sealed and do not have to be replaced when the fittings are disconnected, unless they are worn or damaged.

1. Clean the connector externally with a clean lint free cloth and blow out any road grime with compressed air before disconnecting.
2. Squeeze the retainer tabs and pull the connector apart in a straight line.

NOTE: The retainer will remain on the fuel tube nipple.

NOTE:Fuel rail and fuel pressure regulator fittings can be disconnected using quick disconnect tool 6182 or equivalent. To use tool 6182 or equivalent, slide the tool into the connector until the handle stops against the connector casing, the pull the tubes off. In this case the retainer will remain in the fitting.

Fuel Line Disconnect Tool 6182:

Using Fuel Tube Disconnect Tool No. 6182:

Quick-connect Fitting Assembled:

ASSEMBLY

1. Wipe fuel tube nipple clean and lubricate with clean 30 weight engine oil.
CAUTION: Never insert a fuel tube into a quick-connect fitting without the retainer being either on the tube or in the quick-connect fitting.
2. Push the fuel tube nipple into the fitting until a click is heard.
NOTE: If the connector has "windows" always check the connection of a quick-connect fitting by making sure that the retainer locking "ears" and the fuel tube stop bead are completely visible in the windows, if the connector has windows, and by pulling on the lines to verify a secure connection.

3. Using the DRB II select the Automatic Shut Down (ASD) Fuel System Test to pressurize fuel system and check for leaks. Refer to Powertrain Management/Computers and Control Systems/Testing and Inspection/Procedures

CAUTION: Unless the test is stopped or the ignition switch is turned to the OFF position the fuel pump relay and the ASD relay will remain energized for 7 minutes by the ASD Fuel System Test