Savana 2500 V8-6.0L VIN U (2006)
Fuel Rail: Service and Repair
Fuel Rail Crossover Pipe Replacement
FUEL RAIL CROSSOVER PIPE REPLACEMENT
REMOVAL PROCEDURE
IMPORTANT: The fuel rail for the 5.3L regular production option (RPO) L59 (VIN Z) 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, that includes both the left and right rail assemblies and the
crossover pipe rail.
1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
2. Disconnect the fuel feed (1) and the fuel return (2) pipes from the fuel rail.
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).
INSTALLATION PROCEDURE
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 Service Precautions.
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.
