GM 17113552 Fuel Injection Rail O-Ring Seal Kit 1999-2007

Tools and Materials Needed:

• Fuel Injection Rail O-Ring Kit (17113552): Includes 3 O-rings (2 larger, 1 smaller, typically FKM/Viton material).
• Clean motor oil (for lubricating O-rings).
• Socket set, wrenches, and Torx screwdriver (for fuel rail bolts and crossover tube bracket).
• Flathead screwdriver or pry bar (for gentle prying).
• Non-abrasive cleaner (e.g., carburetor cleaner) and lint-free cloth.
• Torque wrench (for precise reassembly).
• Wheel chocks and 9V battery saver (optional, for safety and preserving vehicle settings).
• Shop rags and a container for small parts.
• Fuel line disconnect tool (if needed for fuel line removal).

Compatibility:

The 17113552 O-ring kit fits GM vehicles (1999-2007), including:

• Chevrolet Silverado 1500/2500/3500 (1999-2007)
• Chevrolet Tahoe/Suburban (2000-2006)
• GMC Sierra 1500/2500 (1999-2007)
• Cadillac Escalade (2002-2006)
• Chevrolet Express 1500/2500/3500 (2003-2007)
• Buick Rainier (2004-2006)
• Others (verify with your service manual).

Note: This kit is specific to the fuel rail crossover tube, not injector O-rings. Confirm fitment for your vehicle’s engine (e.g., 4.8L, 5.3L, 6.0L).

Step-by-Step Instructions:

• Preparation and Safety:
  • Park the vehicle on a flat surface, engage the parking brake, and place wheel chocks around the front tires.
  • Disconnect the negative battery terminal to prevent electrical issues. Optionally, use a 9V battery saver in the cigarette lighter to preserve vehicle settings.
  • Relieve fuel system pressure: Remove the fuel pump fuse or relay, start the engine, and let it stall. Alternatively, use a fuel pressure gauge at the Schrader valve (if equipped) to release pressure safely.
  • Open the hood and ensure a well-ventilated workspace.
• Access the Fuel Rail:
  • Remove the air intake assembly (air filter housing and intake tube) to access the fuel rail.
  • If the intake manifold overlaps the fuel rail (common on some GM engines), remove it per the service manual. This may involve disconnecting throttle body components or other obstructions.
  • Locate the fuel rail crossover tube, which connects the left and right fuel rails across the engine. It’s secured by a Torx screw and hold-down bracket.
• Remove the Fuel Rail Crossover Tube:
  • Disconnect the fuel line from the crossover tube using a fuel line disconnect tool if necessary (varies by model).
  • Remove the Torx screw and hold-down bracket securing the crossover tube.
  • Carefully pull the crossover tube from the fuel rail ends. Use a gentle twisting motion or a small pry bar to avoid damaging the tube or rail. Note the position of the old O-rings (two larger ones at the rail ends, one smaller one at the crossover connection).
• Replace the O-rings:
  • Remove the old O-rings from the crossover tube and rail ends using a flathead screwdriver or pick tool. Inspect for wear, cracking, or swelling, which indicate fuel leaks.
  • Clean the crossover tube and fuel rail mating surfaces with non-abrasive cleaner and a lint-free cloth to remove debris or old O-ring residue.
  • Apply a light coat of clean motor oil to the new O-rings (two larger, one smaller) to aid installation and prevent pinching. Do not use silicone-based lubricants, as they may degrade the O-rings; motor oil is preferred as it’s compatible with fuel exposure.
  • Install the new O-rings: Place the two larger O-rings on the crossover tube ends and the smaller O-ring at the connection point (refer to your service manual for exact placement). Ensure they seat properly without twisting.
• Reinstall the Crossover Tube and Fuel Rail:
  • Reinsert the crossover tube into the fuel rail ends, ensuring a snug fit. The lubricated O-rings should slide in easily; press firmly but don’t force to avoid pinching.
  • Secure the crossover tube with the hold-down bracket and Torx screw. Torque to the specification in your service manual (typically 8-10 ft-lbs for GM fuel rails).
  • Reconnect the fuel line, ensuring a secure click if using quick-connect fittings.
• Reassemble the Engine:
  • Reinstall the intake manifold (if removed), air intake assembly, and any other components.
  • Reconnect the battery and fuel pump fuse/relay.
• Test for Leaks:
  • Turn the ignition to the “ON” position (without starting) to pressurize the fuel system. Check for fuel leaks or odors around the crossover tube and fuel rail.
  • Start the engine and let it idle. Inspect again for leaks. If you smell fuel or see leaks, shut off the engine and recheck O-ring installation for pinching or improper seating.
  • Test drive the vehicle for 10-15 minutes to ensure proper operation. Recheck for leaks after parking.
• Final Checks:
  • Verify no fuel odors or puddles under the hood.
  • Ensure the engine runs smoothly without misfires or hesitation, which could indicate other fuel system issues (e.g., injector O-rings or fuel pressure regulator).

Tips and Warnings:

• Use OEM or high-quality O-rings: The 17113552 kit  uses FKM/Viton material for durability under high pressure (up to 750 psi) and fuel exposure. Avoid cheap aftermarket kits to prevent premature failure.
• Lubricate properly: A light coat of motor oil prevents O-ring damage during installation. Avoid over-lubricating, as slippery O-rings can be dropped or misaligned.
• Check for double O-rings: Ensure no old O-rings remain in the rail or crossover tube, as this can cause leaks.
• Inspect related components: If replacing the crossover tube O-rings, consider checking injector O-rings or the fuel pressure regulator, as leaks in one area may indicate wear in others.
• Torque carefully: Overtightening can damage the fuel rail or crossover tube. Use a torque wrench and follow the service manual.
• Safety first: Fuel is flammable; clean up spills immediately and work in a well-ventilated area with a fire extinguisher nearby.

Troubleshooting:

• Persistent leaks: Check for pinched O-rings, debris in the rail seats, or damaged crossover tube ends. Ensure only one O-ring is installed per position.
• Fuel odor after driving: Recheck torque on the crossover tube bracket and inspect for hairline cracks in the fuel rail.
• Engine misfires: If the issue persists, test the fuel pressure regulator or injector O-rings, as these can cause similar symptoms.

For visual guidance, search YouTube for “GM 5.3L fuel rail crossover tube replacement” or similar videos for your specific model (e.g., 2003 Tahoe).