Fuel Rail Outlet Pipe Replacement

REMOVAL PROCEDURE

IMPORTANT: The fuel rail for the 5.3L regular production option (RPO) L59 (VIN Z) 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 that includes both left and right rail assemblies and the fuel return pipe.




1. Remove the engine sight shield.
2. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
3. Disconnect the fuel feed (1) and fuel return (2) pipes from the fuel rail.




4. Remove the retaining clip attaching screw (4).
5. Remove the crossover fuel pipe retainer clip (5).
6. Remove the fuel return pipe attaching screw (3) and the fuel return pipe retainer (2).
7. Remove the fuel return pipe (1).
8. Remove and discard the fuel return pipe O-ring (6).

INSTALLATION PROCEDURE




1. Lubricate a NEW fuel return pipe O-ring (6) with clean engine oil.
2. Install the fuel return pipe O-ring (6) onto the fuel return pipe (1).
3. Install the fuel return pipe (1).

NOTE: Refer to the Fastener Notice in Service Precautions.

4. Install the fuel return pipe retainer (2) and the fuel return pipe attaching screw (3).
5. Install the crossover fuel pipe retainer clip (5).

IMPORTANT: When installing the retaining clip attaching screw for the crossover pipe, always start the screw by hand. This will prevent consequent stripping of the threads in the rail.

6. Install the retaining clip attaching screw (4).

Tighten
6.1. Tighten the crossover fuel pipe retainer clip attaching screw (4) to 3.8 N.m (34 lb in).
6.2. Tighten the fuel return pipe attaching screw (3) to 5 N.m (44 lb in).




7. Connect the fuel return (2) and the fuel feed (1) pipes to the fuel rail.
8. Tighten the fuel filler cap.
9. Connect the negative battery cable.
10. Use the following procedure in order to inspect for leaks:
10.1. Turn ON the ignition, with the engine OFF, for 2 seconds.
10.2. Turn OFF the ignition for 10 seconds.
10.3. Turn ON the ignition, with the engine OFF.
10.4. Inspect for fuel leaks.
11. Install the engine sight shield.