GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Holden 🢒 2007 🢒 Captiva 🢒 Preface 🢒 Cautions and Notices 🢒 Fuel Return Pipe Replacement

Removal Procedure

    Object Number: 1820564 Size: SH

    Caution: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

  1. Remove the injector return hose.

    2. Object Number: 1820568 Size: SH

    Important: Do not pull the clip out but push it and simultaneously disconnect the injector return hoses. If the clip is removed from the injector, do not reuse the clip.

  2. Disconnect the injection pump return hose.
  3. Disconnect the common rail return hose.
  4. Remove the junction block retaining bolts.
  5. Remove the fuel return line assembly.

Installation Procedure

    Object Number: 1820564 Size: SH
  1. Install the fuel return line assembly.
  2. Connect the common rail return hose.
  3. Connect the injection pump return hose.

    4. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1820568 Size: SH

    Important: Do not compulsorily connect the injector return hoses to the injectors. Push the clip and simultaneously connect the injector return hoses.

  4. Install the junction block.

    5. Tighten
    Tighten the junction block retaining bolts to 11 N·m (97.4 lb in).