Fuel Return Pipe Replacement

Fuel Return Pipe Replacement

Special Tools
* J 43178 Fuel Line Disconnect Tool
* J 44581 Fuel Line Disconnect Tool

Removal Procedure

1. Remove the engine cover.
2. Remove the charge air cooler inlet pipe.
3. Remove the intake manifold tube.
4. Using the J 43178 and J 44581, disconnect the fuel feed and return pipes.




5. Remove the fuel line bracket bolt.




6. Remove the fuel line bracket bolt (1).




7. Remove the fuel line bracket bolt.




8. Disconnect the fuel rail temperature (FRT) sensor electrical connector.




9. Compress the clamp and disconnect the hose from the fuel return line.
10. Disconnect the left fuel return hose from the fuel return pipe.
11. Remove the exhaust gas recirculation (EGR) cooler.




12. Disconnect the right fuel return hose from the fuel return pipe.
13. Remove the pipe bracket bolt.




14. Remove the fuel return pipe from the vehicle.

Installation Procedure




1. Install the fuel return pipe to the vehicle.

Notice: Refer to Fastener Notice.

2. Install the fuel return pipe bracket.

Tighten the bolt to 10 N.m (89 lb in).




3. Install the EGR cooler.
4. Connect the right fuel return hose to the fuel return pipe.




5. Connect the left fuel return hose to the fuel return pipe.
6. Compress the clamp and connect the hose to the fuel return line.




7. Connect the FRT sensor electrical connector.




8. Install the fuel line bracket bolt.

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




9. Install the fuel line bracket bolt (1).

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




10. Install the fuel line bracket bolt.

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

11. Connect the fuel feed and return pipes.
12. Install the intake manifold tube.
13. Install the charge air cooler inlet pipe.
14. Prime the fuel system. Refer to Fuel System Priming.
15. Start the engine.
If the engine does not start, repeat the above step.
16. Inspect the fuel system for fuel leaks.
17. Install the engine cover.