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" Question for you: Any advice on how you got the plastic return line off? Other than just yank on it?"
Assuming you just want to remove the fuelpump/sender assembly:
I disconnected the return line at the coupler. Above the rear axel kinda.
Hose it with WD. Clean it and disconnect.
Then after several reccomendations from this group I....
Pulled the line straight back and to the left untill it was on top of the tank.
Grabbed the end and pulled it to the right.. crossing over the supply line.
Pulled the end up and through the access hole in the deck.
The outer sheath split when I did this.. it seems to be just a insulation layer
and isnt really a intergral part of the line so doesnt pose a leak hazard.
I had the bung nut broke loose but still holding the plate down. I wouldnt want
to work on loosening it with the hose in the way! I hosed it with WD-40 after brushing dirt an crud out of the acces cap then wiped the WD/crud mix up again then hosed it again.. let it sit overnight to allow the WD to soften up the crud that was locking the bung nut in place.
So you dont have to take the hose off to get it out.. it you want to after pulling the assembly.. I am told that a heat gun will soften the hose up and you can remove it from the line... however I got it reinstalled without having to do this.
hope this helps!
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vw bus site - http://www.geocities.com/vw_bus_74/index.html
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