GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 Avalanche - 4WD 🢒 Engine 🢒 Engine Controls - 4.8L, 5.3L, and 6.0L 🢒 Fuel Injection Fuel Rail Crossover Tube Replacement

Fuel Injection Fuel Rail Crossover Tube Replacement 5.3L (L59) Engine

Removal Procedure

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.


    Object Number: 1238585 Size: SH
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  2. Disconnect the fuel feed pipe (1) quick connect fitting from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .

    3. Object Number: 1690737 Size: SH
  3. Remove the retaining clip attaching screw (2, 14) and the crossover fuel pipe retainer clips (3, 15).
  4. Remove the crossover pipe  (1) from the left hand rail assembly (4) and the right hand rail assembly (9).
  5. Remove and discard the crossover fuel pipe O-rings (5, 8).

Installation Procedure

    Object Number: 1690737 Size: SH
  1. Lubricate the NEW crossover fuel pipe O-rings (5, 8) with clean engine oil.
  2. Install the NEW crossover fuel pipe O-rings (5, 8) onto the crossover pipe rail assembly (1).
  3. Install the crossover pipe (1) to the left hand rail assembly (4) and the right hand rail assembly (9).

    4. Notice: Refer to Fastener Notice in the Preface section.

    Important: When installing the retaining clip attaching screws for the crossover pipe, always start them by hand. This will prevent stripping of the threads on the rail.

  4. Install the crossover fuel pipe retainer clips (3, 15). Loosely install the retaining clip attaching screws (2, 14).

    5. Tighten
    Tighten the crossover fuel pipe retainer clip attaching screws (2, 14) to 3.8 N·m (34 lb in).

  5. Install the fuel pressure connection core assembly (6) to the crossover pipe rail assembly (9).

    6. Object Number: 1238585 Size: SH
  6. Connect the fuel feed pipe (1) quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  7. Install the fuel fill cap.
  8. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  9. Use the following procedure in order to inspect for leaks:
    10. 9.1. Turn the ignition ON, with the engine OFF, for 2 seconds.
    9.2. Turn the ignition OFF for 10 seconds.
    9.3. Turn the ignition ON, with the engine OFF.
    9.4. Inspect for fuel leaks.