Fuel and Vapor Return Tubes

 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 shown in the illustration 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 (01610), under vehicle or inside the passenger compartment (lower RH side)
• Front or rear wheel house/fender apron (RH side)

Removal

1. Depressurize fuel system as outlined.

2. Drain fuel from fuel tank (9002) as outlined.

3. Disconnect the push connect fittings from the tubes at the fuel tank .

4. On some vehicles it is necessary to lower the fuel tank and disconnect the push connect fittings from the sender.

5. Remove the RH front fender liner from inside the front wheel housing if required to expose the fuel line routing.

6. Disconnect the spring lock couplings from the engine tubes at the front of the vehicle.

7. Cut the push pins off between each plastic wrap-around clip and the body. Remove the screws from any wrap-around clips. Drill the pop rivets out of any clips. All clips can be reused.

Installation

1. Secure the fuel tube assembly to the underbody near the center of the vehicle using a clip/retainer and pop-rivet. Refer to the appropriate system illustration for the correct location for this first clip.

2. Moving rearward, install all additional clips as shown on the system illustration. The wrap-around clips must be secured with new push-in pins. All clips must be located between the paired upsets located on the fuel tube.

3. Route the tube assembly forward to the front structure and into the RH front wheel housing.

   NOTE: All clips must be located between the paired upsets in the tube assembly.

4. Install the special metal clip and secure it with a screw to retain the tube assembly in the depression under the front structure rearward of the wheel housing.

5. On pressurized fuel systems, connect the plastic tube push connect fittings to the metal tubes or engine tubes at the front of the vehicle and to the fuel tank , fuel pump (9350) and fuel filter (9155) at the rear of the vehicle.

6. Return the drained fuel to the fuel tank as outlined.

7. Check the fuel tubes and push connect fittings for proper function. The push connect fittings must be installed so that the second bead on the tube is inside the end of the fitting. Pull back on the fitting to ensure that it is completely installed.

8. Install the fender liner in the RH front wheel housing.