Fuel Return Line: Service and Repair

Tools Required
Fuel Pipe Separator Tool Set J37088

Notice: Do Not attempt to repair the EVAP pipes or fuel line connecting hoses. If the EVAP pipes or fuel line connecting hoses are damaged, replace them. If the nylon EVAP pipe becomes kinked, and cannot be straightened, it must be replaced.

Removal Procedure
1. Relieve fuel system pressure. Refer to Fuel Pressure Release.

2. Place vehicle on lift.

3. Raise the vehicle.

4. Remove retaining hardware for the section to be replaced.

5. Inspect the location of attaching hardware for installation.





6. Grasp both ends of one fuel pipe connection and twist 1/4 turn in each direction to loosen any dirt in the quick-connect fitting.

7. Repeat for the other fitting.

Caution: Wear safety glasses when using compressed air because flying dirt particles may cause eye injury.





8. Blow out dirt from quick connect fittings using compressed air.





9. Squeeze the plastic tabs of male end connector.





10. Pull connection apart.

11. Install the protective caps on pipe.

Installation Procedure

Caution: 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 it may damage the nylon pipes resulting in a possible fuel leak

^ Before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. (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 pipe in original location.

2. Remove the protective caps from fuel pipe.





3. Apply a few drops of clean engine oil to the male connector pipe end.

4. Install the quick-connect fitting at fuel filter.





4.1. Push connector together to cause the retaining tabs/fingers to snap into place





4.2. Pull on both ends of connection to make sure connection is secure once installed.

5. Install retaining hardware.

6. Lower the vehicle.

7. Repeat the connect procedure for engine compartment fuel pipe quick-connectors.

8. Tighten the fuel filler cap.

9. Install the negative battery terminal.

10. Inspect for leaks.

10.1. Turn the ignition switch ON for 2 seconds.

10.2. Turn the ignition switch OFF for 5 seconds.

10.3. Turn the ignition switch ON.

10.4. Check for fuel leaks.