Fuel Return Tubes, Metal

NOTE: Refer to Push Connect Fittings in this section while servicing fuel tubes. Refer to the appropriate illustrations in this section for proper fuel tube location and orientation.

The 7.3L diesel engine (6007) uses a combination of flexible and steel tubing fuel supply and return tubes. The fuel tube assemblies are secured to the body rails with clips.

A damaged section of tubing longer than 305mm (12 inches) can be cut out of the existing tube assembly and replaced by a comparable service tubing section, spliced into the tube assembly by means of connecting hoses and retaining clamps. A damaged section of tubing shorter than 305mm (12 inches) can be cut out of the tube assembly and replaced by a length of service hose and two retaining clamps.

All replacement hoses must be cut to a length and inside diameter that will ensure proper clamp retention.

Removal

1. Disconnect the damaged tube at both ends.

2. Remove the tube from the holding clips along the frame.

3. Remove all damaged hose and tube sections.

Installation

1. Cut a new section of steel tubing to approximately the same length and inside diameter as the section to be replaced. Allow extra length for flaring the ends of the tubing where required. Square the ends of the cut tubing with a file.

2. Ream the inside edges of the cut tubing with the reamer blade on the tube cutter. Be sure metal chips are removed from inside the tube(s). Double flare the ends of the cut tubing, as required.

3. Bend the tube section to conform to the contour of the original tube. Cut an ample length of hose to form a coupling between the ends of the fuel tubes. Connect the hose couplings to the tubing and install the retaining clamps.

4. Position the tube assemblies in the clips. Connect the tubes and check for leaks.