99 Suburban 5.7 Fuel Leak at Fuel Meter Body

[SAR 99 2wdSuburban]

On my 99 5.7L, after occasionally smelling raw fuel in the engine bay over the past few weeks, I found a minor weep where the fuel lines enter/exit the fuel meter body (on top of the Intake manifold). The leak appears to be coming from the fuel return line, with fuel passing by the O-ring & collecting on top of the fuel meter body (I only found a few drops). Before taking the unit apart, although the retaining nuts were tight, I thought I could detect motion when pulling on the return fuel line, so figured an O-ring had lost its seal.

Thinking it was a simple matter of replacing the O-rings, I went to the dealer & local auto shops looking for replacements - with no luck.

The only part the dealer showed that was even a possible fit was called a fuel line seal kit. However, none was in stock so its on order. My concern is that the dealers description for the assembly where the fuel rails fit into the fuel meter body, while similar, didn't match what I found on taking the unit apart. As well, the dealers part description was poorly labelled so it was difficult to tell if it was for the 5.7L engine or not.

What I found on each of the fuel lines (inlet & outlet) are: Black plastic spacer which slides over the end of the fuel line & held in place by a lip on the fuel line about 1" from the end. Below the spacer is one yellow O-ring which fits between the spacer and the top of the fuel meter body & presumably provides the seal against fuel leakage. The fuel lines are held in place by a 2 bolt retainer which fits around the fuel lines & is holds them in place via pressure on the lip around each fuel line.

The info for the seal kit at the dealer was similar, except that it showed the spacer followed by 3 pieces, rather than the single O-ring I found. It wasn't labelled well, but these could have been retainers plus the O-ring or all O-rings. While I'm pretty sure I didn't miss 2 pieces on each fuel line when taking it apart, I would like to make sure I put it back the way it should be & as there was some doubt at the dealership that the correct part is on order, am not sure I want to rush & install it when it arrives even if it looks more or less OK.

Thx for any assistance in helping me figure out what configuration I should have and I'd appreciate knowing if anyone has been successful in finding replacement O-rings rather than a complete rebuid kit.

[MT-2500]

Make your dealer your best buddie on that one.
If the parts department can not find a good picture of the set up go to the service department and see if they will print out or show you a picture of the o rings and spacers.
Or if someone has a factory service manual it should be in it.
Good luck Mt

[SAR 99 2wdSuburban]

Here's a whoops......... After & getting the part this AM, I went back for another look & found that I had missed the rest of the assembly. What I had taken to be the seat for the yellow O-ring on the top of the fuel meter body turned out to be a stainless steel washer, below which was a black O-ring. So my assembly was as described in the fiche (spacer, yellow O-ring, stainless washer & black O-ring). My only (lame) excuse for missing all the parts is that it's a snug fit, so I didn't notice that it was a washer as it didn't move when I tried to get it out the 1st time.

All re-assembled this AM & 1st test shows it isn't leaking. The only niggle is the cost of the kit - a little steep methinks at $45 Cdn for the parts for the 2 fuel lines, but a lot better than a burnt truck..........

[MT-2500]

Thanks for posting back and letting us know how it went.
Glad all is well on it now.
The 45$ hurts but remember dealer OEM parts is only a one time hurt!!
Good luck
MT