Fuel Return Line: Service and Repair

FUEL HOSE AND PIPE ASSEMBLIES
The fuel feed line is 3/8 inch diameter and the fuel return line is 5/16 inch diameter. Do Not use copper or aluminum tubing to replace steel tubing. Those materials do not have satisfactory durability to withstand normal vehicle vibration.

Coupled hose - These are not to be repaired and are replaced only as an assembly.

Uncoupled hose - Use only reinforced furl resistant hose, made of "Fluoroelastomer" material. Do Not use a hose within 4 inches (100 mm) of any part of the exhaust system, or within 10 inches (254 mm) of the catalytic converter. The hose's inside diameter must match the outside diameter of the steel tubing.

Clamps - These are stainless steel, screw bank-type clamps.

FUEL LINE REPAIR
1. Cut a piece of fuel hose 4 inches (100 mm) longer than the section of line to be removed. If more than 6 inches (152 mm) is to be removed,use a combination of steel pipe and hose. The hose length should not be more than 10 inches total.
2. Cut a section of the pipe to be replaced with a tube cutter. Use the first step of a double flaring tool to form a bead on the ends of the pipe and, also, on the new section of pipe, if used.
3. Slide the hose clamps onto the pipe and push the hose 2 inches (51 mm) onto each portion of the fuel pipe. Tighten a clamp on each side of the repair.
4. Secure fuel line to the frame.
5. Check for leaks.