1989-1995 Toyota SR5 Pickup Fuel Return Line Replacement (1989, 1990, 1991, 1992, 1993, 1994, 1995)

Einleitung

This repair process should be used for repairing a broken or leaking pressure regulator fuel return line on a Toyota vehicle manufactured with a 3VZE engine, typically on the SR5 model manufactured between 1989 and 1995.

Smelling fuel in the cab is a good indication that this line may be leaking. Typically, the smell is worst with the A/C vents on and during or just after startup, as the fuel will have been leaking while the vehicle was off, which allows fuel to pool and create a stronger smell. This leaking fuel poses two main problems; firstly, it can create noxious fumes in the cabin which can create an unsafe driving condition. Secondly, it leaks into the environment surrounding roadways, which negatively impacts those environments.

Toyota Pickups manufactured with the 3VZE engine have a fuel pressure regulator located very close to the engine block. It has a rubber hose that makes a 90 degree corner, and high pressure fuel along with high heat due to its proximity to the engine block causes fairly regular failure of the rubber line.

Before beginning the repair, first check to ensure the return line is what is leaking. To find the return line, refer to step number three of this guide and inspect the line for leaks. It will appear shiny, smell of fuel, be moist, and may have a jet of fuel spraying from it if the engine is running and a pinhole has developed. If it is not leaking, do not continue with this guide.

This guide is relatively simple to complete, and requires no specialized skills.

Was du brauchst

Schritt 1 Pressure Regulator Fuel Return Line

1989-1995 Toyota SR5 Pickup Fuel Return Line Replacement, Pressure Regulator Fuel Return Line: Schritt 1, Bild 1 von 2

1989-1995 Toyota SR5 Pickup Fuel Return Line Replacement, Pressure Regulator Fuel Return Line: Schritt 1, Bild 2 von 2

Pull the hood latch located underneath and left of the steering wheel until it unlatches. An audible "pop" will come from the hood when it has unlatched.

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Schritt 2

1989-1995 Toyota SR5 Pickup Fuel Return Line Replacement: Schritt 2, Bild 3 von 3

Now that the internal latch is opened, a latch underneath the hood must also be unlatched. Put your fingers underneath the hood and lift up on the latch above and right of the Toyota emblem.
Remove the hooked end of the hood propping rod and allow it to pivot at the driver's side; place the hooked end in its receptacle to prop the hood.

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Schritt 3

Inspect the line for damage such as cracks, holes, and fuel seeps.
Continue the repair if it shows signs of these failures. Otherwise, the fuel leak is coming from elsewhere.

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Schritt 4

Use a Phillips #2 Screwdriver to loosen the hose clamps on the line until they move freely and are not constricting the hose.
Do not entirely unscrew the clamps, as they can be difficult to work with when fully unscrewed.

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Schritt 5

1989-1995 Toyota SR5 Pickup Fuel Return Line Replacement: Schritt 5, Bild 3 von 3

Firmly grip the hose and pull one end outwards parallel from the main line. Repeat the process on the other end of the line.

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Schritt 6

Remove the hose clamps from the damaged line. Straighten the used line out and place it alongside the new hose, then cut a piece the same length with the hose cutter (a sharp knife will also work fine).
Place the hose clamps on the new hose. There is no need to replace the old hose clamps.

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