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Home >> Chevrolet >> 2006 >> Cobalt LTZ >> Repair and Diagnosis >> External Pages >> Different car >> Section 680 (Engine Controls And Fuel - 2.4L - Introduction (2 Of 2)) >> Repair Instructions >> Fuel Rail Assembly Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2007 Pontiac G5 Pursuit, 2007 Pontiac G5, and 2007 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
IMPORTANT: Install NEW lower O-rings when reusing fuel injectors. Lubricate the injector tip O-rings prior to installing the injectors into the intake manifold.
    Fig 1: View Of Fuel Injectors
    GM1578472Courtesy of GENERAL MOTORS CORP.
  1. Remove the fuel injectors, if necessary. Refer to Fuel Injector Replacement .
  2. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
    3. NOTE: Refer to Fastener Notice .
  3. Carefully push the fuel injectors into the cylinder head ports.
  4. Install the fuel rail bolts.

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

    5. Fig 2: Identifying Engine Harness Electrical Connector
    GM1647528Courtesy of GENERAL MOTORS CORP.
  5. Connect the engine harness electrical connector (1) to the MAP sensor.
  6. Connect the engine harness electrical connector (2) to the fuel injector harness.
  7. Install the fuel injector harness connector clip to the intake manifold.
    8. Fig 3: View Of Caps Or Plugs, Fuel Line And Fuel Rail
    GM1647977Courtesy of GENERAL MOTORS CORP.
  8. Remove the caps or plugs from the fuel line and the fuel rail.
  9. Connect the fuel feed line quick connect fitting (4) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  11. Inspect for fuel leaks using the following procedure:
    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.
    4. Inspect for fuel leaks.
  12. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
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