Fuel Return Line: Service and Repair

Fuel, Vapor And Return Lines And Components:

FUEL LINE
1. Disconnect the battery negative terminal.
2. Reduce the internal pressure of the fuel lines and hoses by completing the following operations:
a. Disconnect the fuel pump harness connector at the rear of the fuel tank or remove the fuel pump electrical fuse.
b. START and run the engine until it stalls, then turn the ignition switch to OFF.
c. Disconnect the battery negative terminal.
d. Connect the fuel pump harness connector.
3. Remove the bolts that secures the mounting brackets and remove the fuel line.
4. After replacing the fuel line, check for leaks with the line pressurized.

RETURN AND VAPOR LINES
1. Disconnect the fuel line connectors at each end of the line.
CAUTION: Cover with a shop towel to avoid gasoline spillage from any residual fuel in the line.
2. Remove the bolts that secures the mounting brackets and remove the fuel line.
3. After replacing the fuel line, check for leaks during fuel system operation.

FUEL RAIL REMOVAL

Fuel Rail And Components:

1. Disconnect the battery negative terminal.
2. Reduce the internal pressure of the fuel lines and hose by disconnecting the high pressure fuel line from the fuel rail.
CAUTION: Cover with a shop towel to avoid gasoline spillage from any residual fuel in the fuel rail or line.
3. Disconnect the fuel return line from the fuel regulator.
4. Remove the fuel rail mounting bolts.
5. Remove the fuel rail with the injectors and regulator in position. Being careful not to drop any of the injectors while removing the rail.
6. Remove the injectors from the fuel rail.
NOTE: Fuel may spill out of the fuel rail when the injectors are removed.


FUEL RAIL INSTALLATION

Fuel Injector Insulators:

1. Install new insulators to the intake manifold.

Injector Seals:

2. Install new grommets and O-rings to the injectors.
3. Apply unleaded gasoline to the O-ring of the injector.

Injector Installation:

4. While turning the injector to the left and right, install it on to the fuel rail.
5. Be sure the injector turns smoothly.
NOTE: If it does not turn smoothly, the O-ring may be jammed, remove the injector and re-insert it into the fuel rail. Re-check that the injector turns smoothly.

Insulator:

6. When installing the fuel rail, check to be sure that the rail insulator is correctly inserted into the installation holes. Tighten the mounting bolts, and torque to 7-9 lb-ft (10-13 Nm).
7. Bolt the fuel pressure regulator to the fuel rail, and torque the bolts to 7 lb-ft (9 Nm).

Fuel High Pressure Hose Installation:

8. When connecting the high pressure fuel hose and the fuel crossover pipe to the fuel rail, apply fuel to the hose union, and then insert, being careful not to damage the O-ring. Torque the hose connection to 4 lb-ft (5 Nm). Torque the crossover pipe to 7-9 lb-ft (10-13 Nm).
9. After replacement of the fuel rail and injectors, check for leaks with the system pressurized.