Fuel Return Line: Service and Repair

CAUTION: Ford-approved nylon fuel tubing is made from material which has been tested and proven to be acceptable for use with commercially available fuels. It is also resistant to most environmental conditions. Avoid using alternate tubing materials, as this could pose a hazard in service.

CAUTION: Nylon fuel tube must not be serviced using hose and hose clamps. Should the plastic tubes, push connect fittings or steel tube ends become damaged and leak, approved service parts must be used to service the fuel lines.

CAUTION: The plastic fuel lines can be damaged by torches, welding sparks, grinding and other operations which involve heat and high temperatures. If any service operation will be used which involves heat and high temperatures, locate all fuel system components, especially the plastic fuel lines, to ensure they will not be damaged. It is recommended that the plastic fuel tubes be removed from the vehicle if a torch or high heat producing equipment is to be used for service in the following areas:

- Exhaust or suspension components in proximity to fuel tubes.
- Floorpan under vehicle and inside the passenger compartment (RH side).
- Rocker panel (RH side).
- Underbody frames, rails and crossmembers (RH side).
- Dash panel, under vehicle or inside the passenger compartment (lower RH side).
- Front or rear wheel house/fender apron (RH side).

REMOVAL
1. Perform the fuel pressure release procedure. Service and Repair
2. Drain fuel from fuel tank.
3. Disconnect the spring lock couplings from the fuel tubes.
4. Unsnap fuel tubes from plastic retainers in engine compartment.
5. Raise vehicle on hoist.
6. Remove fuel tank.
7. Disconnect fuel supply return and vapor tube push connect fitting from fuel pump module.
8. Remove three fuel line organizers retained to underbody.
9. Remove fuel and vapor return tube from vehicle.

INSTALLATION

Fuel And Vapor Line Routing:

1. Feed the front of the fuel and vapor return tube assembly up between engine and dash panel.
2. Secure fuel and vapor return tube assembly to the underbody by installing three fuel line organizers.
3. Connect fuel supply return and vapor tube push connect fitting to fuel pump module.
4. Install fuel tank.
5. Lower vehicle.
6. Snap in fuel tubes into plastic retainers in engine compartment.
7. Connect the spring lock couplings to the engine compartment tubes.
8. Fill fuel tank.
9. Start engine and check for leaks.