Fuel Return Hose Replacement

Fuel Return Hose Replacement

Removal Procedure

1. Remove the engine cover. Refer to Engine Cover Replacement Service and Repair.

2. Remove the charge air inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement Charge Air Cooler Inlet Pipe Replacement.

3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement Service and Repair.

4. Remove the generator. Refer to Generator Replacement (V8) Service and RepairGenerator Replacement (V6) Service and RepairGenerator Replacement (Diesel) Service and Repair.

5. Remove the A/C compressor bolts and reposition the A/C compressor.




6. Disengage the fuel return line by pulling upward on the cylindrical locking sleeve (1).

7. Remove the fuel return line (2) from the fuel injector (3).

8. Repeat steps 6-7 for the remaining injectors.

9. Remove the fuel return pipe bracket bolt from left valve cover.

10. Disconnect the fuel return hose vacuum line.

11. Remove the fuel return hose clip from back of A/C compressor bracket.

12. Disconnect the fuel return hose from the fuel feed pipe.

13. Remove the return hose from fuel return clip.

14. Remove the fuel return hose vacuum valve from bracket.




15. Remove the fuel injector fuel return line assembly (1).

Installation Procedure




1. Install the fuel injector fuel return line assembly (1).




2. Inspect the O-rings (1) for damage. Replace if necessary.

3. Inspect the fuel return line locking tabs (2) for damage. Replace the fuel return line assembly if necessary.

4. With the cylindrical locking sleeve (3) released in the upward position, install the fuel return line to the fuel injector.

5. Press down on the locking sleeve (3) to secure the connection.

6. Repeat steps 2-5 for the remaining injectors.

7. Install the fuel return hose vacuum valve to bracket.

8. Install the return hose to fuel return hose clip.

9. Connect the fuel return hose to fuel feed pipe.

10. Install the fuel return hose clip to back of A/C compressor bracket.

11. Connect the fuel return hose vacuum line.

12. Install the fuel return pipe bracket bolt to left valve cover.

13. Install the A/C compressor and bolts.

14. Install the generator. Refer to Generator Replacement (V8) Service and RepairGenerator Replacement (V6) Service and RepairGenerator Replacement (Diesel) Service and Repair.

15. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement Service and Repair.

16. Install the charge air inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement Charge Air Cooler Inlet Pipe Replacement.

17. Install the engine cover. Refer to Engine Cover Replacement Service and Repair.