Orlando

Fuel Return Pipe Replacement

Special Tools

EN-6015 Closure Plugs

For equivalent regional tools, refer to Special Tools .

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .
2. Remove the engine sight shield. Refer to Engine Sight Shield Replacement .

Warning: Refer to Petrol/Petrol Vapours Warning in the Preface section.




3. Disconnect the fuel return pipe (1) from the fuel injection pump (2) and unclip from 2 retainer clips. Refer to Plastic Collar Quick Connect Fitting Service .
4. Plug the connections with EN-6015 plugs .



5. Open the upper bulkhead bracket (2).
6. Unclip the fuel return pipe (1) from the bulkhead bracket.
7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
8. Remove the front compartment insulator. Refer to Front Compartment Insulator Replacement .



9. Remove the 4 exhaust pipe front hanger bracket bolts (2).
10. Remove the drivetrain and the front suspension frame bolt (3).
11. Remove the right drivetrain and the front suspension frame support.



12. Unclip the fuel return pipe (1) from the 4 bracket clips (2).



13. Disconnect the fuel return pipe (3) from the fuel return pipe connector (1). Refer to Plastic Collar Quick Connect Fitting Service .
14. Plug the connections with EN-6015 plugs .
15. Unclip the fuel return pipe (3) from the last bracket clip (2).
16. Remove the fuel return pipe (3).

1. Install and position the fuel return pipe (3) and clip it into the last bracket clip (2).
2. Remove the EN-6015 plugs.
3. Connect the fuel return pipe (3) to the fuel return pipe connector (1).



4. Clip in the fuel return pipe (1) to the 4 bracket clips (2).



5. Install the right drivetrain and the front suspension frame support.
6. Install the drivetrain and the front suspension frame bolt (3).
7. Install the 4 exhaust pipe front hanger bracket bolts (2). Refer to Exhaust Pipe Front Hanger Bracket Replacement : 2.0L Diesel LNP .

Caution: Refer to Fastener Caution in the Preface section.

8. Tighten the drivetrain and the front suspension frame bolt (3) to 160 N·m (118 lb ft).
9. Install the front compartment insulator. Refer to Front Compartment Insulator Replacement .
10. Lower the vehicle.



11. Clip in the fuel return pipe (1) to the upper bulkhead bracket (2).
12. Close the upper bulkhead bracket.



13. Remove the EN-6015 plugs.
14. Connect the fuel return pipe (1) to the fuel injection pump (2) and clip it into 2 retainer clips.
15. Install the engine sight shield. Refer to Engine Sight Shield Replacement .
16. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection : without Start/Stop System .