Fuel Return Line: Service and Repair

Fuel Hose/Pipes Replacement - Chassis

Removal Procedure

Note: Clean the fuel connection and surrounding areas prior to disconnecting the lines in order to avoid possible system contamination.




1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (Service and Repair).
2. Remove the brake master cylinder and reposition. Refer to Master Cylinder Replacement (Master Cylinder Replacement).
3. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (Without CH 48027) (Fuel Pressure Relief (Without CH 48027))Fuel Pressure Relief (With CH 48027) (Fuel Pressure Relief (With CH 48027)).
4. Disconnect the fuel feed line (1) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).




5. Open the fuel/brake pipe retainers (1).
6. Remove the fuel feed line from the fuel/brake pipe retainers (1).
7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).




8. Remove the fuel/brake line retainer bolt.
9. Remove the fuel feed line from the retainer.




10. Remove the fuel/brake line push in retainer from the underbody.
11. Remove the fuel feed line from the retainer.




12. Remove the fuel/brake line retainer bolts.
13. Remove the fuel feed line from the retainer.




14. Open the fuel/brake line retainer (1).
15. Remove the fuel feed line from the retainer.




16. Disconnect the fuel feed (3) and evaporative emission (EVAP) (4) lines from the fuel tank lines (1, 2). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
17. Remove the fuel feed line.

Installation Procedure




1. Position the fuel feed line.
2. Connect the fuel feed (3) and EVAP (4) lines to the fuel tank lines (1, 2). Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




3. Install the fuel feed line to the retainer.
4. Close the fuel/brake line retainer (1).




5. Install the fuel feed line to the retainer.

Caution: Refer to Fastener Caution (Fastener Caution).

6. Install the fuel/brake line retainer bolts.

Tighten the bolts to 10 Nm (89 lb in).




7. Install the fuel feed line to the retainer.
8. Install the fuel/brake line push in retainer to the underbody.




9. Install the fuel feed line to the retainer.
10. Install the fuel/brake line retainer bolt.

Tighten the bolt to 10 Nm (89 lb in).

11. Lower the vehicle.




12. Install the fuel feed line to the fuel/brake pipe retainers (1).
13. Close the fuel/brake pipe retainers (1).




14. Connect the fuel feed line (1) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
15. Position and install the brake master cylinder. Refer to Master Cylinder Replacement (Master Cylinder Replacement).
16. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement (Service and Repair).
17. Install the fuel fill cap.
18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (RPO LS4) (Service and Repair)Battery Negative Cable Disconnection and Connection (RPOs LZE/LZ4/LZ8) (Service and Repair).
19. Perform the following steps to inspect for leaks:

1. Turn ON the ignition for 2 seconds.
2. turn OFF the ignition for 10 seconds.
3. Turn ON the ignition.
4. Inspect the system for leaks.

20. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement (Service and Repair).