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

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.

1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
2. Disconnect the fuel feed pipe quick connect fitting from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .



3. Remove the fuel return pipe attaching screw (3) and the fuel return pipe retainer (2).
4. Remove the fuel return pipe (1).
5. Remove and discard the fuel return pipe O-ring (6).
6. Remove the fuel pressure connection core assembly (24) from the crossover pipe rail (25).
7. Remove the retaining clip attaching screw (22) and the crossover fuel pipe retainer clip (21).
8. Remove the retaining clip attaching screw (4) and the crossover fuel pipe retainer clip (5).
9. Remove the crossover pipe rail assembly (25) from the left hand rail assembly (14) and the right hand rail assembly (15).
10. Remove and discard the crossover fuel pipe O-rings (7, 20).

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).

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.

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 on 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 on 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 (4, 22) to 3.8 N·m (34 lb in).
2. Tighten the fuel return pipe attaching screw (3) to 5 N·m (44 lb in).
10. Install the fuel pressure connection core assembly (24) to the crossover pipe rail assembly (25).



11. Connect the fuel feed pipe quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
12. Install the fuel fill cap.
13. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
14. Use the following procedure in order to inspect for leaks:

14.1.

Turn the ignition ON, with the engine OFF, for 2 seconds.

14.2.

Turn the ignition OFF for 10 seconds.

14.3.

Turn the ignition ON, with the engine OFF.

14.4.

Inspect for fuel leaks.