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Home >> Chevrolet >> 2006 >> Cobalt LTZ >> Repair and Diagnosis >> External Pages >> Different car >> Section 790 (Engine Mechanical - 2.0L) >> Repair Instructions - Off Vehicle >> Fuel Rail and Injectors Installation

Fuel Rail and Injectors Installation

WARNING: This page is about a different car, the 2008 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Identifying Fuel Rail Bolt Tightening Sequence
    GM1769965Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel rail with injectors into the cylinder head evenly.
  2. Hand tighten the 2 outer fuel rail bolts to seat the injector into the injector bores.
    3. NOTE: Refer to Fastener Notice .
  3. Start and hand tighten the remaining fuel rail bolts.

    Tighten: 

    • Tighten the fuel rail bolts in sequence to 22 N.m (16 lb ft).
    • Tighten the fuel rail bolts in sequence a second time to 22 N.m (16 lb ft).

    4. Fig 2: View Of Fuel Injector Insulator
    GM1769947Courtesy of GENERAL MOTORS CORP.
  4. Install the fuel injector noise insulator.
  5. Connect the electrical harness to the fuel rail harness connection.
    6. Fig 3: View Of High Pressure Fuel Pump Roller Lifter
    GM1769961Courtesy of GENERAL MOTORS CORP.
  6. Lubricate the high pressure fuel pump cylinder head bore with 5W30 engine oil.
    7. IMPORTANT: Ensure that the high pressure fuel pump roller lifter is oriented properly, the camshaft is at base circle, and the number 1 piston is at top dead center (TDC) on the exhaust stroke. The distance from the mounting flange surface to the camshaft at base circle should be 52 mm (2.05 in).
  7. Lubricate the high pressure fuel pump roller lifter with 5W30 engine oil and install into the cylinder head bore.
    8. Fig 4: Identifying High Pressure Fuel Pump & Bolts
    GM1769960Courtesy of GENERAL MOTORS CORP.
  8. Install a NEW high pressure fuel pump gasket.
  9. Install a NEW high pressure fuel pump O-ring.
    10. IMPORTANT: Ensure the plastic bolt retainers are installed in the high pressure fuel pump mounting holes before installing.
  10. Install the high pressure fuel pump.
  11. Start and hand-tighten the high pressure fuel pump bolts evenly.

    Tighten:  Tighten the high pressure fuel pump bolts evenly to 15 N.m (11 lb ft).

    12. Fig 5: Identifying High Pressure Fuel Line
    GM1769948Courtesy of GENERAL MOTORS CORP.
  12. Install and hand-tighten both ends of the NEW high pressure fuel line.

    Tighten:  Tighten the high pressure fuel line fitting nuts to 30 N.m (22 lb ft).

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