Aveo 2006-2007

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



  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.  

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine appearance cover.
  6.  
  7. Disconnect the electronic throttle control connector.
  8.  
  9. Disconnect the intake air temperature (IAT) sensor.
  10.  
  11. Disconnect the camshaft position (CMP) sensor.
  12.  
  13. Disconnect the manifold absolute pressure (MAP) sensor.
  14.  
  15. Disconnect the fuel injector harness connectors.
  16.  
  17. Remove the purge solenoid valve to intake manifold hose.
  18.  
  19. Remove the MAP sensor vacuum hose.
  20.  
  21. Remove the upper intake manifold bracket.
  22.  
  23. Disconnect the fuel supply line.
  24.  
  25. Disconnect the throttle body outlet coolant hose.
  26.  
  27. Remove the fuel rail mounting bolts.
  28.  
  29. Remove the fuel rail with the fuel injectors attached.
  30.  
  31. Remove the fuel injector retaining clips.
  32.  
  33. Remove the fuel injectors by pulling down and out.
  34.  
  35. Discard the fuel injector O-rings.
  36.  

To install:

  1. Lubricate the new fuel injector O-rings with engine oil and install the new O-rings on the fuel injectors.
  2.  
  3. Install the fuel injectors into the fuel rail sockets with the fuel injector terminals facing outward.
  4.  
  5. Install the fuel injector retainer clips onto the fuel injectors and the fuel rail ledge.
    NOTE
    Make sure that the clip is parallel to the fuel injector harness connector.

  6.  
  7. Install the fuel rail assembly into the cylinder head. Tighten the fuel rail mounting bolts to 18 ft. lbs. (25 Nm).
  8.  
  9. Connect the throttle body coolant hose.
  10.  
  11. Connect the fuel supply line.
  12.  
  13. Install the intake manifold upper bracket with the bolts.
  14.  
  15. Install the MAP sensor vacuum hose.
  16.  
  17. Install the purge solenoid to intake manifold hose.
  18.  
  19. Connect the fuel injector harness connectors. Rotate each fuel injector as required to avoid stretching the wiring harness.
  20.  
  21. Connect the MAP sensor connector, CMP sensor and IAT sensor.
  22.  
  23. Connect the electronic throttle control connector.
  24.  
  25. Install the engine appearance cover.
  26.  
  27. Connector the negative battery cable.
  28.  
  29. Start the engine and check for leaks.
  30.  

 
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