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. Refer to Engine Cover Replacement (Service and Repair).
2. Remove the charge air cooler inlet pipe. Refer to Charged Air Cooler Hoses/Pipes Replacement (Inlet) (Charged Air Cooler Hoses/Pipes Replacement (Inlet))Charged Air Cooler Hoses/Pipes Replacement (Outlet) (Charged Air Cooler Hoses/Pipes Replacement (Outlet)).
3. Remove the intake manifold tube. Refer to Intake Manifold Tube Replacement (LMM) (Service and Repair).
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. Refer to Exhaust Gas Recirculation Valve Cooler Replacement (Exhaust Gas Recirculation Valve Cooler Replacement).




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.

Caution: Refer to Fastener Caution (Fastener Caution).

2. Install the fuel return pipe bracket and tighten to 10 Nm (89 lb in).




3. Install the EGR cooler. Refer to Exhaust Gas Recirculation Valve Cooler Replacement (Exhaust Gas Recirculation Valve Cooler Replacement).
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 and tighten to 25 Nm (18 lb ft).




9. Install the fuel line bracket bolt (1) and tighten to 25 Nm (18 lb ft).




10. Install the fuel line bracket bolt and tighten to 25 Nm (18 lb ft).
11. Connect the fuel feed and return pipes.
12. Install the intake manifold tube. Refer to Intake Manifold Tube Replacement (LMM) (Service and Repair).
13. Install the charge air cooler inlet pipe. Refer to Charged Air Cooler Hoses/Pipes Replacement (Inlet) (Charged Air Cooler Hoses/Pipes Replacement (Inlet))Charged Air Cooler Hoses/Pipes Replacement (Outlet) (Charged Air Cooler Hoses/Pipes Replacement (Outlet)).
14. Prime the fuel system. Refer to Fuel System Priming (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. Refer to Engine Cover Replacement (Service and Repair).