Cavalier, Sunfire 2001-2005

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



2.2L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Be careful when removing the fuel rail so that you do not damage the injector tips or electrical connections.



    Air cleaner outlet resonator
     
    Vacuum pipe from the fuel pressure regulator
     
    Fuel pressure regulator, on 2004-05 models
     
    Engine fuel supply and return pipes
     
    Fuel injector harness connectors
     
    Fuel rail attaching studs.
     

  6.  
  7. Remove the fuel rail as follows:
    1. Pull the fuel rail back and upward to remove the fuel injectors from the ports.
    2.  
    3. Rotate the fuel rail to position the injectors downward.
    4.  
    5. Remove the fuel rail.
    6.  

  8.  
  9. Remove or disconnect the following:

    Fuel injector retainer clip
     
    Fuel injector from the fuel rail
     

  10.  
  11. Inspect the fuel injector in order to determine if the upper O-ring was also removed. If the upper O-ring in not removed, remove the O-ring from the fuel rail assembly.

    Fuel injector O-rings and discard
     

  12.  

To install:

  1. Install or connect the following:
    NOTE
    The fuel injector will click when the injector is installed correctly.



    O-rings on the fuel injector
     
    Fuel injector clip on the fuel injector
     



    Fuel injector to the fuel rail with the connector facing upward
     

  2.  
  3. Install the fuel rail as follows:
    1. With the fuel injectors positioned downward, lower the fuel injectors into the ports.
    2.  
    3. Align the injectors by rotating the fuel rail forward.
    4.  
    5. Carefully push the fuel injectors into the cylinder head ports.
    6.  
    7. Install and tighten the fuel rail retainers to 89 inch lbs. (10 Nm).

      Fuel injector harness connectors. Gently pull on the connectors to make sure they are fully engaged.
       
      Fuel supply and return pipes
       
      Fuel pressure regulator, on 2004 models and tighten the bolt to 89 inch lbs. (10 Nm)
       
      Vacuum pipe to the fuel pressure regulator
       
      Air cleaner outlet resonator
       
      Negative battery cable
       

    8.  

  4.  
  5. Inspect for fuel leaks using the following procedure:


    1. Turn ON the ignition, with the engine OFF for 2 seconds.
    2.  
    3. Turn OFF the ignition for 10 seconds.
    4.  
    5. Turn OFF the ignition.
    6.  
    7. Inspect for fuel leaks.
    8.  

  6.  

 
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