Fuel Return Pipe Replacement

FUEL RETURN PIPE REPLACEMENT

REMOVAL PROCEDURE




1. Remove the engine wiring harness.
2. Remove the water outlet bolts.
3. Remove the water outlet from the thermostat housing crossover.
4. Remove the exhaust gas recirculation (EGR) cooler tube.
5. Reposition the fuel return line hose clamps (1).
6. Remove the fuel return line hoses from the return line.




7. Remove the fuel return line clamp bolts (1).
8. Reposition the fuel return line hose clamp (3) from the fuel rail.
9. Remove the fuel return line hose from the fuel rail.
10. Remove the fuel return line (2).

INSTALLATION PROCEDURE




1. Install the fuel return line (2).
2. Install the fuel return line hose to the fuel rail.
3. Position the fuel return line hose clamp (3) at the fuel rail.

NOTE: Refer to Fastener Notice.

4. Install the fuel return line clamp bolts (1).

Tighten the bolts to 25 N.m (18 lb ft).




5. Install the fuel return line hoses to the return line.
6. Position the fuel return line hose clamps (1).
7. Install the EGR cooler tube.
8. Install the water outlet bolts.
9. Install the water outlet to the thermostat housing crossover.
10. Install the engine wiring harness.
11. Prime the fuel system. Refer to Fuel System Priming.
12. Start the engine. If the engine stalls, repeat the above step.
13. Once the engine starts, inspect for fuel leaks.