Fuel Return Line: Service and Repair

Fuel Pressure ReleaseWARNING: Do not smoke or carry lit tobacco or an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in personal injury.

NOTE: A damaged section of tubing can be cut out of an existing line and replaced with a comparable service tubing section, spliced into the line by means of threaded fasteners and connectors.

CAUTION: The use of copper tubing is not recommended due to fuel contamination.

REMOVAL
1. Perform fuel pressure release procedure. Fuel Pressure Release
2. Drain the fuel from the fuel tank.
3. Disconnect the line(s) at the fuel tank and at the engine. Remove the lines from the holding clips along the underbody. Remove all damaged hoses and tube sections.

INSTALLATION
1. Cut a new section of tubing approximately the same length as the section to be replaced, allowing for the threaded connectors/fasteners.
2. Bend the tube section to conform to the contour of the original tube.
3. Square the ends of the cut tubing with a file. Remove burrs. Blow out any particles with compressed air.
4. Position the lines in the underbody clips. Do not tighten at this time.

NOTE: After disassembly of the flareless fitting joint, such as at the fuel hose to fuel line connection, the flareless fitting can be reassembled. To reassemble, reconnect the threaded fitting and seat the ferrule to be finger-tight. When the ferrule is seated, draw the nut up approximately one-sixth to one-third of a turn with a wrench to complete the tightening operation.

5. Assemble the fitting by sliding the nut over the tubing with the threaded (open) end out.

CAUTION: Make sure that the ferrule is assembled correctly before installing it on the tube.

Ferrule:

6. Slide the ferrule onto the tubing with the cutting edge out. The large head end should be inside of the nut.
7. Lubricate the ferrule and the threads on the fasteners with oil.
8. Bottom the tube in the fitting, and tighten the nut until the ferrule just grips the tube. When the tube can no longer be turned by hand, the ferrule has started to grip the tube.
9. After the ferrule grips the tube, tighten the nut one full turn.
10. Tighten the fuel line to the underbody clips to secure the fuel lines.
11. Fill the fuel tank and check for leaks.