Express 2500 V8-5.3L VIN T (2005)
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).
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. 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.
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.
