Arctic2
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As part of the maintenance program I am doing on the FL 1 I recently acquired/bought, i decided to change the fuel return hose and it's plastic unions as they have been know to snap off at the T junction when changing the PCV filter, or changing the an injector or even doing a leak back test.
Below is how i changed them.
First remove the small section of the engine/injector cover by removing the three 8mm small bolts. Fig 1
1
Once remove this will reveal the fuel return hose and the unions Fig 2
2
Put the small engine cover safe to one side along with it's bolts Fig 3
3
You will then need to remove the air/intercooler cover by disconnecting the hoses from air intake, and the intercooler Fig 4
4
Start at the EGR by undoing the jubilee clip Fig 5
5
Loosen or remove the first fixing hold the intake to the engine Fig 6
6
Next the left intercooler hose clip Fig 7/8
7
8
You then remove the air intake pipe section Fig 9
9
The last screw to remove is the left intake fixing Fig 10/11
10
11
Unplug the wiring from the top section of the intake Fig 12
12
with wiring sheath removed you can disconnect the intake for the air cleaner cover Fig 13
13
Next you can disconnect the intake from the EGR hose and put it safe with the engine cover from earlier Fig 14
14
You now need to remove wiring plugs for the injectors this will consist of remove the tiny star shaped bolts first, if you do not have the tool for this you can use a 5mm socket it will do the job Fig 15/16
15
16
With the three bolts remove and put safe, you now need to unclip the wiring plugs from the injectors Fig 17
17
Unplug each one in turn you can use a thin blade screwdriver to open the clip if you so wish, but there is a press section as you will see to help the plugs remove Fig 18
18
Set the wiring to one side out of the way as you can see i was changing the air filter at the same time so i moved it into that section of the air cleaner
Fig 19
19
I/we/you can now unplug the fuel return hose from the injectors start with the far right one as you look at them Fig 20
20
The retaining clips can either be pushed in to remove the union or you can as did remove the clips with some long nosed pliers Fig 21
21
Pull on the union and is should pull out from the injector Fig 22
22
If the union is a bit stiff use a fine thin blade screwdriver to tease it apart as here Fig 23
23
repeat this for all the return hose unions until they are all removed Fig 24
24
At the very last union disconnect from the fuel line as here Fig 25
25
Now that the fuel return hoses and unions are removed as here below you are ready to copy them but with brass unions Fig 26
26
With your new hose line next to the old hose you can start to build up the new brass line section Fig 27
27
Put the first brass union on the end of the new hose line this will be the dead end union Fig 28
28
With the first union in place you can now do your first cut of the new hose making sure it is the same length as the old original hose Fig 29
29
Repeat this along the new hose line each time adding a new bras T union Fig 30
30
Once you have completed the four unions the new fuel hose line is ready to be fitted back into the injectors Fig 31
31
Now the hose line with it's new brass unions is ready first push the union back into the fuel line then line them up to fit into the injectors Fig 32
32
Push each union back into the relative injector, repeat along the line from left to right, making sure they a fully pushed home Fig 33
33
Finally fit the clips to hold the unions in place the return hose brass union job is now completed and they should last the life time of the car Fig 34/35
34
35
Refit the injector wiring harness making sure each one is plug in properly Fig 36
36/37
37
Screw down the harness to it's fixing points Fig 38
38
Refit the intake and it's hoses along with the small engine cover Figs 39/40
39
40
Cheers Arctic2
Link for the brass unions and fuel hose below
http://stores.ebay.co.uk/dieselcomponentsuk
Below is how i changed them.
First remove the small section of the engine/injector cover by removing the three 8mm small bolts. Fig 1
Once remove this will reveal the fuel return hose and the unions Fig 2
Put the small engine cover safe to one side along with it's bolts Fig 3
You will then need to remove the air/intercooler cover by disconnecting the hoses from air intake, and the intercooler Fig 4
Start at the EGR by undoing the jubilee clip Fig 5
Loosen or remove the first fixing hold the intake to the engine Fig 6
Next the left intercooler hose clip Fig 7/8
You then remove the air intake pipe section Fig 9
The last screw to remove is the left intake fixing Fig 10/11
Unplug the wiring from the top section of the intake Fig 12
with wiring sheath removed you can disconnect the intake for the air cleaner cover Fig 13
Next you can disconnect the intake from the EGR hose and put it safe with the engine cover from earlier Fig 14
You now need to remove wiring plugs for the injectors this will consist of remove the tiny star shaped bolts first, if you do not have the tool for this you can use a 5mm socket it will do the job Fig 15/16
With the three bolts remove and put safe, you now need to unclip the wiring plugs from the injectors Fig 17
Unplug each one in turn you can use a thin blade screwdriver to open the clip if you so wish, but there is a press section as you will see to help the plugs remove Fig 18
Set the wiring to one side out of the way as you can see i was changing the air filter at the same time so i moved it into that section of the air cleaner
Fig 19
I/we/you can now unplug the fuel return hose from the injectors start with the far right one as you look at them Fig 20
The retaining clips can either be pushed in to remove the union or you can as did remove the clips with some long nosed pliers Fig 21
Pull on the union and is should pull out from the injector Fig 22
If the union is a bit stiff use a fine thin blade screwdriver to tease it apart as here Fig 23
repeat this for all the return hose unions until they are all removed Fig 24
At the very last union disconnect from the fuel line as here Fig 25
Now that the fuel return hoses and unions are removed as here below you are ready to copy them but with brass unions Fig 26
With your new hose line next to the old hose you can start to build up the new brass line section Fig 27
Put the first brass union on the end of the new hose line this will be the dead end union Fig 28
With the first union in place you can now do your first cut of the new hose making sure it is the same length as the old original hose Fig 29
Repeat this along the new hose line each time adding a new bras T union Fig 30
Once you have completed the four unions the new fuel hose line is ready to be fitted back into the injectors Fig 31
Now the hose line with it's new brass unions is ready first push the union back into the fuel line then line them up to fit into the injectors Fig 32
Push each union back into the relative injector, repeat along the line from left to right, making sure they a fully pushed home Fig 33
Finally fit the clips to hold the unions in place the return hose brass union job is now completed and they should last the life time of the car Fig 34/35
Refit the injector wiring harness making sure each one is plug in properly Fig 36
Screw down the harness to it's fixing points Fig 38
Refit the intake and it's hoses along with the small engine cover Figs 39/40
Cheers Arctic2
Link for the brass unions and fuel hose below
http://stores.ebay.co.uk/dieselcomponentsuk
Last edited:
should have added that at the end so will go back and edit it, 
