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Fuel Rail Crossover Pipe (5.3L): Installation

WARNING: This page is about a different car, the 2003 Oldsmobile Bravada, 2003 GMC Envoy XL, 2003 GMC Envoy, and 2003 Chevrolet TrailBlazer. However, it is still accessible from the selected car via links, so may be relevant.
  1. Lubricate the NEW crossover fuel pipe "O" rings (7, 20) with clean engine oil. See Figure.
  2. Install the NEW crossover fuel pipe "O" rings (7, 20) onto the crossover pipe rail assembly (25).
  3. Install the crossover pipe rail assembly (25) to the left hand rail assembly (14) and the right hand rail assembly (15).
    CAUTION: When installing the retaining clip attaching screws for the crossover pipe, always start them by hand. This will prevent consequent stripping of the threads on the rail.
  4. Install the crossover fuel pipe retainer clip (21). Loosely install the retainer clip attaching screw (22).
  5. Lubricate the NEW fuel return pipe "O" ring (6) with clean engine oil.
  6. Install the NEW fuel return pipe "O" ring (6) on the fuel return pipe (1).
  7. Install the fuel return pipe (1).
  8. Install the fuel return pipe retainer (2). Loosely install the fuel return pipe attaching screw (3).
  9. Install the crossover fuel pipe retainer clip (5). Loosely install the retainer clip attaching screw (4). Tighten to specification. See TORQUE SPECIFICATIONS .
  10. Tighten the crossover fuel pipe retainer clip attaching screws (4, 22) to specification. See TORQUE SPECIFICATIONS .
  11. Tighten the fuel return pipe attaching screw (3) to specification. See TORQUE SPECIFICATIONS .
  12. Install the fuel pressure connection core assembly (24) to the crossover pipe rail assembly (25).
  13. Connect the fuel feed and return pipes (1) to the fuel rail. See Figure. See FUEL LINE DISCONNECT FITTINGS (5.3L) .
  14. Install the fuel fill cap.
  15. Connect the negative battery cable.
  16. Use the following procedure in order to inspect for leaks:
    • Turn the ignition ON, with the engine OFF, for 2 seconds.
    • Turn the ignition OFF for 10 seconds.
    • Turn the ignition ON, with the engine OFF.
    • Inspect for fuel leaks.
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