Fuel Return Line: Service and Repair

WARNING: FUEL SUPPLY LINES ON ALL VEHICLES EQUIPPED WITH FUEL INJECTED ENGINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. FUEL SYSTEM PRESSURE MUST BE RELIEVED PRIOR TO FUEL SYSTEM SERVICE TO PREVENT POSSIBLE INJURY. REFER TO FUEL PRESSURE RELEASE.

The individual stainless steel tubes of the fuel and vapor return tube are secured together by the manufacturer and are supplied as an assembly. The fuel and vapor return tube is attached to the body with locators and screws. The fuel and vapor return tube is connected to the fuel filter and base and Evaporative Emissions canister (EVAP canister) using push-connects. Connections to the engine are made with spring lock couplings.

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. Use of non-approved tubing could pose a hazard in service and may not comply with the Clean Air Act.
- Nylon fuel tube must not be serviced using hose and hose clamps. Push connect fittings cannot be serviced except to replace the retaining clips. 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.
- The nylon 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 nylon fuel lines, to be certain they will not be damaged. It is recommended that the nylon 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.
- floor pan 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 Fuel Pressure Release procedure.
2. Cut straps which retain fuel and vapor return tube in engine compartment as necessary.
3. Disconnect spring lock couplings from fuel injection supply manifold and evaporative emission canister purge valve (EVAP canister purge valve).
4. Raise vehicle on hoist.
5. Disconnect push-connect fittings from fuel tank filler pipe shield, fuel filter and base and rear fuel supply return and vapor tube at RH side of fuel tank.
6. Remove retaining screws retaining locator brackets to floorpan and remove fuel and vapor return tubes.

INSTALLATION
1. Install fuel and vapor return tube and retaining screws securing locator brackets to floorpan. Tighten screws to 5-7 Nm (45-61 lb-in).
2. Connect fuel tank filler pipe shield and rear fuel supply return and vapor tube to the fuel and vapor return tube.
3. Connect fuel and vapor return tube to fuel filter and base.
4. Lower vehicle on hoist.
5. Connect fuel line spring lock coupling to evaporative emission canister purge valve and fuel injection supply manifold.
6. Start engine. Check for leaks.