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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 947 (Engine Controls - 4.8L, 5.3L, & 6.0L (Introduction)) >> Repair Instructions >> Fuel Rail Crossover Pipe Replacement (5.3L (L59) Engine) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. 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.
  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).
    NOTE: Refer to Fastener Notice in Cautions and Notices.
    IMPORTANT: 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 retaining 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).
    IMPORTANT: 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.
  9. Install the crossover fuel pipe retainer clip (5). Loosely install the retaining clip attaching screw (4).

    Tighten: 

    1. Tighten the crossover fuel pipe retainer clip attaching screws (4, 22) to 3.8 N.m (34 lb in).
    2. Tighten the fuel return pipe attaching screw (3) to 5 N.m (44 lb in).

  10. Install the fuel pressure connection core assembly (24) to the crossover pipe rail assembly (25).
    11. Fig 1: Exploded View Of Fuel Rails & Injector Components
    GM350543Courtesy of GENERAL MOTORS CORP.
  11. Connect the fuel feed pipe quick connect fitting to the fuel rail. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
  12. Install the fuel fill cap.
  13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure (Single Battery) or Battery Negative Cable Disconnect/Connect Procedure (Auxiliary Battery) in Engine Electrical.
  14. Use the following procedure in order to inspect for leaks:
    1. Turn the ignition ON, with the engine OFF, for 2 seconds.
    2. Turn the ignition OFF for 10 seconds.
    3. Turn the ignition ON, with the engine OFF.
    4. Inspect for fuel leaks.
    15. Fig 2: Identifying Fuel Feed & EVAP Pipes
    GM1238585Courtesy of GENERAL MOTORS CORP.
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