Fuel Return Line: Service and Repair

Fuel Hose/Pipes Replacement - Chassis

Removal Procedure
Warning: Refer to Fuel and Evaporative Emission Pipe Warning (Technician Safety Information).

Warning: Refer to Gasoline/Gasoline Vapors Warning (Service Precautions).


Caution: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution (Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution).




1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH-48027) (Fuel Pressure Relief (With CH 48027))Fuel Pressure Relief (Without CH-48027) (Fuel Pressure Relief (Without CH-48027)).
2. Disconnect the chassis fuel feed line quick connect fitting (2) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
3. Disconnect the chassis evaporative emission (EVAP) line quick connect fitting (1) from the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
5. Remove the fuel pipe bracket nut (3) from the transmission stud.
6. Remove the fuel pipe bracket from the stud.




7. Disconnect the fuel tank fuel feed line quick connect fitting (4) from the chassis fuel feed line. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
8. Disconnect the EVAP line quick connect fitting (1) from the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
9. Remove the chassis fuel feed and EVAP line bracket bolt (2).
10. Lift the chassis fuel feed and EVAP line assembly (3) up in order the remove the bracket tab from the crossmember.




11. Remove the fuel feed and EVAP line clip (4) from the fuel line bracket.
12. Remove the fuel pipe bracket bolt (6).
13. Remove the fuel feed and EVAP pipe assembly (3) from the vehicle.

Installation Procedure




1. Install the fuel feed and EVAP pipe assembly (3) to the vehicle.

Caution: Refer to Fastener Caution (Fastener Caution).

2. Position the fuel pipe bracket (5) and install the bracket bolt (6).

Tighten the bolt to 4.5 Nm (40 lb in).

3. Install the fuel feed and EVAP line clip (4) to the fuel line bracket.




4. Position the chassis fuel feed and EVAP line assembly (3) bracket tab to the crossmember.
5. Install the chassis fuel feed and EVAP line bracket bolt (2).

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

6. Connect the EVAP line quick connect fitting (1) to the chassis EVAP line. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).
7. Connect the fuel tank fuel feed line quick connect fitting (4) to the chassis fuel feed line. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).




8. Install the fuel pipe bracket onto the stud.
9. Install the fuel pipe bracket nut (3) to the transmission stud.

Tighten the nut to 9 Nm (80 lb in).

10. Lower the vehicle.
11. Connect the chassis fuel feed line quick connect fitting (2) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service (Metal Collar Quick Connect Fitting Service).
12. Connect the chassis EVAP line quick connect fitting (1) to the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service (Plastic Collar Quick Connect Fitting Service).