2003 Chevrolet SSR BaseFACTORY OEM SERVICE PROCEDURE

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 crossover fuel pipe O-rings (7, 20) on the crossover pipe (25).
  3. Install the crossover pipe (25) to the left fuel rail (14) and the right fuel rail (15).
  4. Install the crossover fuel pipe to the right fuel rail retainer clip (21). Loosely install the retainer clip attaching screw (22).
  5. Lubricate the new fuel return pipe O-ring (6) with clean engine oil.
  6. Install the fuel return pipe O-ring (6) on the fuel return pipe (1).
  7. Install the fuel return pipe (1) to the left fuel rail (14).
  8. Install the fuel return pipe retainer (2). Loosely install the fuel return pipe attaching screw (3).
  9. Install the crossover fuel pipe to left fuel rail retainer clip (5). Loosely install the retainer 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 (25).
    11. Fig 2: View Of Rear Of Engine Fuel Pipe Connections
    GM300360Courtesy of GENERAL MOTORS CORP.
  11. Connect the fuel return pipe (2) and the fuel feed pipe (1) to the fuel rail.
  12. Tighten the fuel filler 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.
  16. Install the engine sight shield. Refer to Engine Sight Shield Replacement in Engine Mechanical.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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