GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Generic 🢒 2003 🢒 Unit Repair 🢒 Engine 🢒 Engine Controls - 4.8L, 5.3L, and 6.0L 🢒 Fuel Rail Outlet Pipe Replacement

Removal Procedure

    Object Number: 300360 Size: SH
  1. Relieve the fuel system pressure. Refer to the Fuel Pressure Relief .
  2. Disconnect the fuel feed (1) and fuel return (2) pipes from the fuel rail.

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

  3. Install the fuel return pipe (1).
  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).

    6. 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).

    7. Tighten

    1. Tighten the crossover fuel pipe retainer clip attaching screw (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
  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:
    11. 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.