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GMC Yukon XLModel years 2000–2006

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Fuel systemModel years 2005–2005ManufacturerGovernment

Engine fuel rail crossover tube retainer screws may break (5.3L RPO L59) - recall 04V-376

Certain sport utility vehicles and pickup trucks with 5.3L (RPO L59) V8 engines; the NHTSA record lists GMC Yukon XL 2005. The recall text says no U.S. Tahoe or Yukon vehicles are in the U.S. campaign (Canadian vehicles are in the GM bulletin). Model years come from the NHTSA record's product list held in the database, not from the recall text.

FaultCrate・Engine fuel rail crossover tube retainer screws may break (5.3L RPO L59) - recall 04V-376

The engine fuel rail crossover tube retainer screws were not manufactured to specification and may break.

The failed screw was harder than specification; the over-hardening came from a conveyor in an induction hardening operation at the fastener plant stopping or slowing excessively, exposing the screws to the hardening for too long.

What to do

  1. Check for leaks: ignition ON with the engine OFF for 2 seconds, ignition OFF for 10 seconds, ignition ON with the engine OFF, then visually inspect for fuel leaks.
  2. Dealers inspect the fuel rail crossover tube and replace the retainer screws if necessary.
  3. Hold the fuel crossover tube retainer to the bracket on the fuel rail with locking pliers, using enough force to keep the retainer from moving without damaging any parts.
  4. Remove the fuel rail crossover tube bracket retainer screw on one side and dispose of it properly.
  5. Remove the two new screws from the retainer kit (P/N 89017590) and discard the remaining retainer brackets from the kit.
  6. Part number 89017590, RETAINER KIT, F/INJN FUEL RL C/OVR TUBE, quantity 1 per vehicle.
  7. Start the new screw by hand for at least 3 full turns into the fuel rail crossover tube retainer bracket.
  8. Torque the screw to 4.8Nm (42 lb in).
  9. Check that the retainer is seated and not loose by trying to wiggle it slightly; it should not move. Then re-torque the screw to 4.8Nm (42 lb in).
  10. Repeat steps 5 through 10 on the other side of the crossover tube.

Part numbers printed in the document

The numbers are as the document prints them. The name and the replacing number are what the pages of GMPartsGiant, a reseller of genuine parts and not GM, state. Aftermarket equivalents are not checked here (the links only search by number). Confirm the fit for the vehicle (VIN) before ordering.

If left

  • If a screw breaks, fuel could leak from the crossover joint, the engine may stall, and with an ignition source an engine compartment fire could occur.→ fuel leak, engine stall, engine compartment fire

Caution

  • The GM bulletin lists Tahoe and Yukon models because Canadian vehicles are included in the bulletin.
  • No U.S. Tahoe or Yukon vehicles are included in the U.S. campaign.
  • Do not remove the crossover tube from the fuel rail or disturb the o-ring seal, because a fuel leak may result.
  • The service procedure in this recall differs from the one in the service manual.

In the records

  • Fuel Rail Crossover Tube: repaired 1
  • Retainer Screw: replaced 1

Applies to

  • The recall concerns sport utility vehicles and pickup trucks with 5.3L (RPO L59) V8 engines.
See the evidence (2 documents, 18 passages)
DocumentPublisherDate
[1]Recall 04V376000: FUEL SYSTEM, GASOLINE:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS ↗
GovernmentNHTSA
2004-08-02
[2]Recall 04V-376: documents filed with NHTSA ↗
ManufacturerGeneral Motors (the documents of the recall as filed with NHTSA: defect notice, dealer bulletin)
—

  • Applies toThe recall concerns sport utility vehicles and pickup trucks with 5.3L (RPO L59) V8 engines.

    ON CERTAIN SPORT UTILITY VEHICLES AND PICKUP TRUCKS EQUIPPED WITH 5.3L (RPO L59) V8 ENGINES,— [1]

  • Why it happensThe engine fuel rail crossover tube retainer screws were not manufactured to specification and may break.

    THE ENGINE FUEL RAIL CROSSOVER TUBE RETAINER SCREWS WERE NOT MANUFACTURED TO SPECIFICATIONS AND MAY BREAK.— [1]

  • If leftIf a screw breaks, fuel could leak from the crossover joint, the engine may stall, and with an ignition source an engine compartment fire could occur.

    IF THE TUBE RETAINER SCREW BREAKS, FUEL COULD LEAK FROM THE FUEL RAIL CROSSOVER JOINT, THE ENGINE MAY STALL AND, IF AN IGNITION SOURCE WERE PRESENT, AN ENGINE COMPARTMENT FIRE COULD OCCUR.— [1]

  • RepairDealers inspect the fuel rail crossover tube and replace the retainer screws if necessary.

    DEALERS WILL INSPECT THE FUEL RAIL CROSSOVER TUBE AND, IF NECESSARY, REPLACE THE RETAINER SCREWS.— [1]

  • CautionThe GM bulletin lists Tahoe and Yukon models because Canadian vehicles are included in the bulletin.

    NOTE: THE GM BULLETIN LISTS THE TAHOE AND YUKON MODELS BECAUSE CANADIAN VEHICLES ARE INCLUDED IN THE BULLETIN.— [1]

  • CautionNo U.S. Tahoe or Yukon vehicles are included in the U.S. campaign.

    NO U.S. TAHOE OR YUKON VEHICLES ARE INCLUDED IN THE U.S. CAMPAIGN.— [1]

  • Why it happensThe failed screw was harder than specification; the over-hardening came from a conveyor in an induction hardening operation at the fastener plant stopping or slowing excessively, exposing the screws to the hardening for too long.

    It was determined that the failed screw was harder than specification. Additional investigation disclosed that the over hardening had occurred due to a conveyor in an induction hardening operation at a Textron fastener plant stopping or slowing excessively, causing excessive exposure of screws to the induction hardening.— [2]

  • CautionDo not remove the crossover tube from the fuel rail or disturb the o-ring seal, because a fuel leak may result.

    Notice: Do not remove the crossover tube from the fuel rail or disturb the o-ring seal as a fuel leak may be produced.— [2]

  • CautionThe service procedure in this recall differs from the one in the service manual.

    IMPORTANT: The service procedure contained in this recall is different from the service procedure found in the appropriate service manual.— [2]

  • RepairHold the fuel crossover tube retainer to the bracket on the fuel rail with locking pliers, using enough force to keep the retainer from moving without damaging any parts.

    Secure the fuel crossover tube retainer to the bracket on the fuel rail with locking type pliers (Figure 1). Use sufficient force to keep the retainer from moving without damaging any parts.— [2]

  • RepairRemove the fuel rail crossover tube bracket retainer screw on one side and dispose of it properly.

    Remove the fuel rail crossover tube bracket retainer screw on one side and properly dispose of the removed screw.— [2]

  • RepairRemove the two new screws from the retainer kit (P/N 89017590) and discard the remaining retainer brackets from the kit.

    Remove the two new screws from the retainer kit (P/N 89017590) and discard the remaining retainer brackets from the kit.— [2]

  • RepairPart number 89017590, RETAINER KIT, F/INJN FUEL RL C/OVR TUBE, quantity 1 per vehicle.

    89017590 | RETAINER KIT, F/INJN FUEL RL C/OVR TUBE | 1— [2]

  • RepairStart the new screw by hand for at least 3 full turns into the fuel rail crossover tube retainer bracket.

    Install the new screw by hand for at least 3 full turns into the fuel rail crossover tube retainer bracket.— [2]

  • RepairTorque the screw to 4.8Nm (42 lb in).

    Torque the screw to 4.8Nm (42 lb in).— [2]

  • RepairCheck that the retainer is seated and not loose by trying to wiggle it slightly; it should not move. Then re-torque the screw to 4.8Nm (42 lb in).

    Verify that the retainer is properly seated and not loose trying to slightly wiggle the retainer. The retainer should not move. Re-torque the screw to 4.8Nm (42 lb in)— [2]

  • RepairRepeat steps 5 through 10 on the other side of the crossover tube.

    Repeat steps 5 through 10 on the other side of the crossover tube.— [2]

  • How to confirmCheck for leaks: ignition ON with the engine OFF for 2 seconds, ignition OFF for 10 seconds, ignition ON with the engine OFF, then visually inspect for fuel leaks.

    a. Turn the ignition ON, with the engine OFF, for 2 seconds. b. Turn the ignition OFF for 10 seconds. c. Turn the ignition ON, with the engine OFF. d. Visually inspect for fuel leaks.— [2]

Put together by FaultCrate from public records and technical documents. The cause and the repair are for the workshop to decide with the vehicle in front of it. Counts are records, not failure rates.

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