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Home >> Chevrolet >> 2005 >> Chevy Express G3500, Van Passenger Extended >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System - 4.8L, 5.3L, And 6.0L - Introduction >> Repair Instructions >> Fuel Rail Crossover Pipe Replacement >> Installation Procedure
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Installation Procedure

    Fig 1: Exploded View Of Fuel Rails & Injector Components
    GM350543Courtesy of GENERAL MOTORS CORP.
  1. Lubricate the NEW crossover fuel pipe O-rings (7, 20) with clean engine oil.
  2. Install the NEW crossover fuel pipe O-rings (7, 20) onto the crossover pipe rail assembly (25).
  3. Install the crossover pipe rail assembly (25) to the left hand rail assembly (14) and the right hand rail assembly (15).
    NOTE: Refer to Fastener Notice in Cautions and Notices.
    IMPORTANT: When installing the retaining clip attaching screws for the crossover pipe, always start them by hand. This will prevent consequent stripping of the threads in the rail.
  4. Install the crossover fuel pipe retainer clip (21). Loosely install the retaining clip attaching screw (22).
  5. Lubricate the NEW fuel return pipe O-ring (6) with clean engine oil.
  6. Install the NEW fuel return pipe O-ring (6) on the fuel return pipe (1).
  7. Install the fuel return pipe (1).
  8. Install the fuel return pipe retainer (2). Loosely install the fuel return pipe attaching screw (3).
    IMPORTANT: When installing the retaining clip attaching screws for the crossover pipe, always start them by hand. This will prevent consequent stripping of the threads in the rail.
  9. Install the crossover fuel pipe retainer clip (5). Loosely install the retaining clip attaching screw (4).

    Tighten: 

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

  10. Install the fuel pressure connection core assembly (24) to the crossover pipe rail assembly (25).
    11. Fig 2: View Of Rear Of Engine Fuel Pipe Connections
    GM300360Courtesy of GENERAL MOTORS CORP.
  11. Connect the fuel return (2) and fuel feed (1) pipes to the fuel rail.
  12. Tighten the fuel fill cap.
  13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  14. Use the following procedure in order to inspect for leaks:
    1. Turn ON the ignition, with the engine OFF, for 2 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition, with the engine OFF.
    4. Inspect for fuel leaks.
  15. Install the fuel pressure connection cap.
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