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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) >> Removal Procedure

Removal 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.
IMPORTANT: The fuel rail for the 5.3L regular production option (RPO) L59 (VIN Z) engine is compatible with fuel that has a composition of up to 85 percent Ethanol (E85). Because of this, the fuel rail will be serviced as an entire assembly, this includes both left and right rail assemblies and crossover pipe rail.
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
    2. Fig 1: Identifying Fuel Feed & EVAP Pipes
    GM1238585Courtesy of GENERAL MOTORS CORP.
  2. Disconnect the fuel feed pipe quick connect fitting from the fuel rail. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
  3. Remove the fuel return pipe attaching screw (3) and the fuel return pipe retainer (2).
  4. Remove the fuel return pipe (1).
  5. Remove and discard the fuel return pipe O-ring (6).
  6. Remove the fuel pressure connection core assembly (24) from the crossover pipe rail (25).
  7. Remove the retaining clip attaching screw (22) and the crossover fuel pipe retainer clip (21).
  8. Remove the retaining clip attaching screw (4) and the crossover fuel pipe retainer clip (5).
  9. Remove the crossover pipe rail assembly (25) from the left hand rail assembly (14) and the right hand rail assembly (15).
  10. Remove and discard the crossover fuel pipe O-rings (7, 20).
    11. Fig 2: Exploded View Of Fuel Rails & Injector Components
    GM350543Courtesy of GENERAL MOTORS CORP.
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