Fuel Return Line: Service and Repair

Engine Compartment Fuel Lines:

Fuel Pipes:

CAUTION:

a. If nylon fuel feed or return lines become kinked, or damaged in any way, they must be replaced.
b. DO NOT attempt to repair sections of nylon fuel lines. If damaged replace with new part.
c. Tools required for engine compartment fuel feed and/or return line quick-connect fittings: J 37088 Fuel Line Separator Tool Set (or equivalent).

REMOVAL

1. Disconnect the negative battery terminal.
2. Relieve fuel system pressure. Refer to MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELIEF.
3. Disconnect the quick-connect fittings at the engine compartment fuel feed and return lines:
a. Grasp both ends of one fuel line connection and twist 1/4 turn in each direction to loosen any dirt in the quick-connect fitting. Repeat for other fitting. Blow out the quick-connect fittings with compressed air.

WARNING: Safety glasses must be worn when using compressed air, as flying dirt particles may cause eye injury.

b. Choose the correct tool from the tool set for the size of fitting.
c. Insert tool into female connector, then push inward to release the male connector.
d. Repeat for the other fitting.
4. Remove the fuel pipe attaching hardware.
5. Remove the fuel feed and return pipe nuts at the TBI unit.
6. Remove the fuel feed and return pipes and o-rings. discard O-rings.

INSTALLATION

1. Install new O-rings on the fuel feed and return pipes.
2. Install the fuel feed and return pipes to the TBI. Finger tight only.
3. Install the fuel pipe attaching hardware.
4. Tighten the fuel pipe attaching nuts to 27.0 Nm (20.0 lb.ft.).

WARNING: To reduce the risk of fire and personal injury: Before connecting fuel line quick-connect fittings, always apply a few drops of engine oil to the male tube ends. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the o-rings inside the female connector will swell and may prevent proper reconnection if not lubricated.

4. Apply a few drops of clean engine oil to the male connector tube ends.
5. Install fuel feed and return line quick-connect fittings:
a. Push the connectors together to cause the retaining tabs/fingers to snap into place.
b. Once installed, pull on both sides to make sure they are secure.
6. Tighten the fuel filler cap.
7. Reconnect the negative battery terminal.
8. Turn the ignition switch to the ON position for 2 seconds, then turn to OFF for 5 seconds. Again, turn to the ON position, and check for fuel leaks.