Fuel Return Line: Service and Repair

Fuel Hoses/Pipes Replacement - Filter to Tank

Removal Procedure

Notice: Refer to Cover and Plug Openings Notice in Service Precautions.

Important: Always maintain cleanliness when servicing fuel system components.




1. Remove the fuel tank.
2. Note the position of the fuel, the evaporative emission (EVAP) pipes and the attaching hardware for installation.
3. Disconnect the fuel feed (2), the fuel return (2) and the EVAP pipe quick-connect fittings at the fuel sender assembly.
4. Cap the fuel sender fuel pipes and the in-pipe fuel filter pipes as needed to stop any fuel leakage.
5. Remove the fuel feed, the fuel return and the EVAP pipe attaching hardware.
6. Remove the fuel feed (2), the fuel return (2) and the EVAP pipes from the fuel tank.

Installation Procedure

Caution: In order to Reduce the Risk of Fire and Personal Injury: If nylon fuel pipes are nicked, scratched or damaged during installation, they must be replaced.

Notice: Refer to Fuel System Ground Notice in Service Precautions.

Notice:
* Secure the fuel pipes to the frame in order to prevent chafing. Maintain a minimum of 13 mm (1/2 inch) clearance around a pipe in order to prevent contact and chafing. Maintain a minimum of 19 mm (3/4 inch) around any moving part.

* Do not allow the fuel pipes to come into contact with the fuel tank or underbody.




1. Install the new fuel feed (2), the fuel return (2) and the EVAP pipes to the fuel tank.
2. Install the fuel feed, the fuel return and the EVAP pipe attaching hardware.
3. Remove the caps from the in-pipe fuel filter pipes and the fuel sender fuel pipes.
4. Connect the fuel feed (2), the fuel return (2) and the EVAP pipe quick-connect fittings at the fuel sender assembly.
5. Ensure that all of the fuel pipe bundle clips, and fasteners are properly installed.
6. Install the fuel tank.