Fuel Return Pipe Replacement

Fuel Return Pipe Replacement

Removal Procedure





1. Remove the water outlet. Refer to Water Outlet Tube Replacement (LMM) (Service and Repair) .
2. Remove the intake manifold tube. Refer to Intake Manifold Tube Replacement (Service and Repair) .
3. Remove the glow plug control module and bracket. Refer to Glow Plug Control Module Replacement (Service and Repair) .
4. Remove the fuel temperature sensor. Refer to Fuel Temperature Sensor Replacement (Service and Repair) .
5. Reposition the fuel hose clamp (1) at the fuel return pipe.




6. Remove the fuel hose (1) from the return pipe.






Note

Engine wiring harness shown removed for clarity.

7. Reposition the fuel return hose clamp (2) at the fuel return pipe.




8. Remove the fuel return pipe clip bolt (2) and clip.
9. Remove the fuel return pipe clamp bolt (1) and bracket.




10. Reposition the fuel return hose clamp (1) at the return pipe.
11. Remove the fuel return hose from the return pipe.
12. Remove the fuel return pipe clamp bolt (2) and clamp.
13. Disconnect the fuel injection fuel feed pipe (3) from the fuel return pipe.






Note

Note the routing of the fuel return pipe prior to removal.

14. Remove the fuel return pipe from the fuel return hose and the vehicle.



Installation Procedure







Note

Ensure to route the fuel return pipe under the wiring harness and noted during removal.

1. Position and install the fuel return pipe to the vehicle and the fuel return hose.




2. Connect the fuel injection fuel feed pipe (3) to the fuel return pipe.
Caution: Refer to Fastener Caution (Fastener Caution) .
3. Position and install the fuel return pipe clamp and bolt (2).

Tighten the bolt to 24 Nm (18 lb ft).

4. Install the fuel return hose to the return pipe.
5. Position the fuel return hose clamp (1) at the return pipe.




6. Install the fuel return pipe bracket, clamp, and bolt (1).

Tighten the bolt to 24 Nm (18 lb ft).

7. Install the fuel return pipe clip and bolt (2).

Tighten the bolt to 24 Nm (18 lb ft).





8. Position the fuel return hose clamp (2) at the fuel return pipe.




9. Install the fuel hose (1) to the return pipe.




10. Position the fuel hose clamp (1) at the fuel return pipe.
11. Install the fuel temperature sensor. Refer to Fuel Temperature Sensor Replacement (Service and Repair) .
12. Install the glow plug control module and bracket. Refer to Glow Plug Control Module Replacement (Service and Repair) .
13. Install the intake manifold tube. Refer to Intake Manifold Tube Replacement (Service and Repair) .
14. Install the water outlet. Refer to Water Outlet Tube Replacement (LMM) (Service and Repair) .
15. Prime the fuel system. Refer to Fuel System Priming (Fuel System Priming) .
16. Start the engine. If the engine stalls, repeat the above step.
17. Once the engine starts, inspect for fuel leaks.