GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2004 🢒 TrailBlazer - 2WD 🢒 Engine 🢒 Engine Controls - 4.8L, 5.3L, and 6.0L 🢒 Fuel Rail Outlet Pipe Replacement

Removal Procedure

    Object Number: 856643 Size: SH
  1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
  2. Disconnect the fuel return pipe (1) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .

    3. Object Number: 350543 Size: SH
  3. Remove the retaining clip attaching screw (4).
  4. Remove the crossover fuel pipe retainer clip (5).
  5. Remove the fuel return pipe attaching screw (3) and the fuel return pipe retainer (2).
  6. Remove the fuel return pipe (1).
  7. Remove and discard the fuel return pipe O-ring (6).

Installation Procedure

    Object Number: 350543 Size: SH
  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).
  4. Install the fuel return pipe retainer (2) and the fuel return pipe attaching screw (3).

    5. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

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

    6. Tighten

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

    Object Number: 300360 Size: SH
  6. Connect the fuel return pipe (1) 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.