Aveo 2004-2005

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



  1. Disconnect the negative battery cable.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove the intake manifold support bracket.
  6.  
  7. Disconnect the fuel injector harness connectors.
  8.  
  9. Disconnect the fuel feed line.
  10.  
  11. Remove the fuel rail, with injectors attached.
  12.  
  13. Remove the retaining clips and remove the injectors by pulling downward and out.

    Click image to see an enlarged view

    Fig. Fuel injectors and fuel rail-1.6L engine

  14.  

To install:

  1. Lubricate new O-rings with clean engine oil and position onto the injectors.
  2.  
  3. Install the fuel injectors on the fuel rail with the injector terminals facing outward.
  4.  
  5. Install the retaining clips.
  6.  
  7. Install the fuel rail. Tighten the bolts to 18 ft. lbs. (25 Nm).
  8.  
  9. Connect fuel feed line.
  10.  
  11. Connect the fuel injector connectors.
  12.  
  13. Install the intake manifold bracket.
  14.  
  15. Start the engine and check for fuel leaks.
  16.  

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the intake manifold support bracket.
  6.  
  7. Disconnect the fuel injector harness connectors.
  8.  
  9. Disconnect the fuel feed line.
  10.  
  11. Remove the fuel rail, with injectors attached.
  12.  
  13. Remove the retaining clips and remove the injectors by pulling downward and out.

    Click image to see an enlarged view

    Fig. Fuel injectors and fuel rail-1.6L engine-2005-06 models

  14.  

To install:

  1. Lubricate new O-rings with clean engine oil and position onto the injectors.
  2.  
  3. Install the fuel injectors on the fuel rail with the injector terminals facing outward.
  4.  
  5. Install the retaining clips.
  6.  
  7. Install the fuel rail. Tighten the bolts to 18 ft. lbs. (25 Nm).
  8.  
  9. Connect fuel feed line.
  10.  
  11. Connect the fuel injector connectors.
  12.  
  13. Install the intake manifold bracket.
  14.  
  15. Start the engine and check for fuel leaks.
  16.  

 
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