Fuel Return Line: Service and Repair

Fuel Hose/Pipes Replacement - Chassis

Tools Required

J 45059 Angle Meter

Removal Procedure




1. Remove the intake manifold cover.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) Fuel Pressure Relief (Without CH 48027).
3. Disconnect the fuel feed pipe (1) quick connect fitting from the fuel rail.




4. Cap or plug the fuel feed pipe and the fuel rail in order to prevent system contamination.
5. Open the upper retainer (1) and remove the fuel feed pipe from the retainer.
6. Open the retainers (2, 3) attached to the studs on the front of dash and remove the fuel feed pipe.
7. Raise and support the vehicle. Refer to Vehicle Lifting.




8. Disconnect the fuel feed pipe (2) line quick connect fitting from the fuel tank line.




9. Remove the side rail reinforcement bolts (1).




10. Remove the front frame bolts (1).
11. Remove the side rail reinforcements (3).




12. Remove the rear brake pipe bracket nuts and release the brackets from the body studs.
13. Release the pipe retainers from the vehicle underbody.
14. Remove the fuel feed pipe from the pipe retainers.
15. Lower the rear of the pipe while moving the pipe rearward slightly, then lower the front of the pipe.
16. Remove the fuel feed pipe from the vehicle.

Installation Procedure




1. Position the fuel feed pipe to the vehicle.
2. With the rear of the pipe positioned slightly rearward and down, raise the front of the pipe into position.
3. Install the remainder of the pipe into position.
4. Install the fuel feed pipe to the pipe retainers.
5. Secure the pipe retainers to the vehicle underbody.




6. Position the side rail reinforcements (3) to the side rail and frame.

Notice: Refer to Fastener Notice.

7. Install the front frame bolts (1).

Tighten the bolts to 100 N.m (73 lb ft) plus an additional 180 degrees using J 45059.




8. Install the side rail reinforcement bolts (1).

Tighten the bolts to 50 N.m (37 lb ft).




9. Connect the fuel feed pipe (2) line quick connect fitting to the fuel tank line.




10. Lower the vehicle.
11. Remove the caps or plugs from the fuel feed pipe and the fuel rail.
12. Install the fuel feed pipe to the retainers (2, 3) and close the retainers.
13. Install the fuel feed pipe to the upper retainer (1) and close the retainer.




14. Connect the fuel feed pipe (1) quick connect fitting to the fuel rail.
15. Connect the negative battery cable.
16. Inspect for fuel leaks using the following procedure:

1. Turn ON the ignition, with the engine OFF for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition, with the engine OFF.
4. Inspect for fuel leaks.

17. Install the intake manifold cover.