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Home >> Chevrolet >> 2006 >> Cobalt SS, 4D Sedan, Standard >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - 2.4L - Introduction (2 Of 2) >> Repair Instructions >> Fuel Rail Assembly Replacement >> Installation Procedure

Installation Procedure

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: Removing 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: Connecting Engine Harness Electrical Connector To Fuel Injector Harness
    GM1647528Courtesy of GENERAL MOTORS CORP.
  5. Connect the engine harness electrical connector (2) to the fuel injector harness.
  6. Install the fuel injector harness connector clip to the intake manifold.
    7. Fig 3: Removing Caps Or Plugs From Fuel Line And Fuel Rail
    GM1647977Courtesy of GENERAL MOTORS CORP.
  7. Remove the caps or plugs from the fuel line and the fuel rail.
  8. Connect the fuel feed line quick connect fitting (4) to the fuel rail. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
  9. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure .
  10. 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.
  11. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
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