Cobalt 2006-2008, G5 2007

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the coolant overflow pipe.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Use a back up wrench on the fuel rail and disconnect the fuel supply pipe.
  8.  
  9. Remove the fuel rail attaching studs.
    WARNING
    Use care when removing the fuel rail assembly in order to prevent damage to the fuel injectors electrical connector terminals and spray tips.



    Click image to see an enlarged view

    Fig. Fuel rail and injectors-2.0L engine

  10.  
  11. Remove the fuel rail using the following procedure:
    1. Pull the fuel rail back and upward to remove the fuel injectors from the cylinder head ports.
    2.  
    3. Rotate the fuel rail in order to position the injectors downward.
    4.  
    5. Remove the fuel rail.
    6.  

  12.  
  13. Disconnect the fuel injector harness connectors.
  14.  
  15. Remove the fuel injector retainer clip.
  16.  
  17. Remove the fuel injectors from the fuel rail.
    NOTE
    Visually inspect the fuel injector in order to determine if the upper O-ring was also removed. If the upper O-ring is not removed, remove the O-ring from the fuel rail assembly.

  18.  
  19. Remove and discard the fuel injector O-rings.
  20.  

To install:


NOTE
Always install new injector O-rings when servicing the fuel injectors. Lubricate the new injector O-rings with clean engine oil

  1. Install the O-rings on the fuel injector.
  2.  
  3. Install the fuel injector clip on the fuel injector.
    NOTE
    The fuel injector will click when the injector is installed correctly.

  4.  
  5. Install the fuel injector in the fuel rail with the connector facing upward.
  6.  
  7. Connect the fuel injector harness connectors. Pull back to insure the connectors are locked in place.
    NOTE
    Install new lower O-rings when reusing fuel injectors. Lubricate the injector tip O-rings prior to installing the injectors into the intake manifold.

  8.  
  9. Install the fuel rail using the following procedure:
    1. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head 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.  

  10.  
  11. Install the fuel rail attaching studs. Tighten the fuel rail studs to 89 inch lbs. (10 Nm).
  12.  
  13. Install the fuel supply pipe. Using a backup wrench on the fuel rail tighten the fuel supply pipe to 10 ft. lbs. (14 Nm).
  14.  
  15. Install the coolant overflow pipe. Tighten the pipe bolt to 71 inch lbs. (8 Nm).
  16.  
  17. Connect the negative battery cable.
  18.  
  19. 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 ON the ignition.
    6.  
    7. Inspect for fuel leaks.
    8.  

  20.  

2.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove the air cleaner outlet resonator.
  6.  
  7. Disconnect the fuel line fitting.
  8.  
  9. Disconnect the fuel injector harness connectors.
  10.  
  11. Remove the fuel rail attaching studs.
    NOTE
    Use care when removing the fuel rail assembly in order to prevent damage to the fuel injectors electrical connector terminals and spray tips.



    Click image to see an enlarged view

    Fig. Fuel rail removal-2.2L engine

  12.  
  13. Remove the fuel rail using the following procedure:
    1. Pull the fuel rail back and upward to remove the fuel injectors from the cylinder head ports.
    2.  
    3. Rotate the fuel rail in order to position the injectors downward.
    4.  
    5. Remove the fuel rail.
    6.  

  14.  
  15. Remove the fuel injector retainer clip.
  16.  
  17. Remove the fuel injectors from the fuel rail.
    NOTE
    Visually inspect the fuel injector in order to determine if the upper O-ring was also removed. If the upper O-ring is not removed, remove the O-ring from the fuel rail assembly.



    Click image to see an enlarged view

    Fig. Fuel injectors-2.2L engine

  18.  
  19. Remove and discard the fuel injector O-rings.
  20.  

To install:


NOTE
Always install new injector O-rings when servicing the fuel injectors. Lubricate the new injector O-rings with clean engine oil.

  1. Install the O-rings on the fuel injector.
  2.  
  3. Install the fuel injector clip on the fuel injector.
    NOTE
    The fuel injector will click when the injector is installed correctly.

  4.  
  5. Install the fuel injector in the fuel rail with the connector facing upward.
    NOTE
    Install new lower O-rings when reusing fuel injectors. Lubricate the injector tip O-rings prior to installing the injectors into the intake manifold.

  6.  
  7. Install the fuel rail using the following procedure:
    1. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head 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.  

  8.  
  9. Install the fuel rail attaching studs. Tighten the fuel rail studs to 89 inch lbs. (10 Nm).
  10.  
  11. Connect the fuel injector harness connectors. Pull back to insure the connectors are locked in place.
  12.  
  13. Connect the fuel line fitting.
  14.  
  15. Install the air cleaner outlet resonator.
  16.  
  17. Connect the negative battery cable..
  18.  
  19. 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 ON the ignition.
    6.  
    7. Inspect for fuel leaks.
    8.  

  20.  

2.4L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Relieve the fuel system pressure. Refer to Relieving Fuel System Pressure.
  6.  
  7. Remove the air cleaner outlet duct.

    Click image to see an enlarged view

    Fig. Disconnect the fuel feed line quick connect fitting (4) from the fuel rail

  8.  
  9. Disconnect the fuel feed line quick connect fitting (4) from the fuel rail.
  10.  
  11. Cap or plug the fuel line and the fuel rail to prevent contamination.
  12.  
  13. Disconnect the engine harness electrical connector from the fuel injector harness.
  14.  
  15. Remove the fuel injector harness connector clip from the intake manifold.
  16.  
  17. Disconnect the engine harness electrical connector from the Manifold Absolute Pressure (MAP) sensor.
  18.  
  19. Remove the fuel rail bolts.
    WARNING
    Use care when removing the fuel rail assembly in order to prevent damage to the fuel injector electrical connector terminals and spray tips.

  20.  
  21. Pull the fuel rail back and upward to remove the fuel injectors from the cylinder head ports.
  22.  
  23. Remove the fuel rail.
  24.  
  25. Remove the fuel injectors.

    Click image to see an enlarged view

    Fig. Remove the fuel rail bolts and fuel rail-2.4L Engine

  26.  

To install:


NOTE
Install NEW lower O-rings when reusing fuel injectors. Lubricate the injector tip O-rings prior to installing the injectors into the intake manifold.

  1. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
  2.  
  3. Carefully push the fuel injectors into the cylinder head ports.
  4.  
  5. Install the fuel rail bolts. Tighten the bolts to 89 inch lbs. (10 Nm).
  6.  
  7. Connect the engine harness electrical connector to the MAP sensor.
  8.  
  9. Connect the engine harness electrical connector to the fuel injector harness.
  10.  
  11. Install the fuel injector harness connector clip to the intake manifold.
  12.  
  13. Remove the caps or plugs from the fuel line and the fuel rail.
  14.  
  15. Connect the fuel feed line quick connect fitting (4) to the fuel rail.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Inspect for fuel leaks using the following procedure:
    1. Turn the ignition switch ON, but do not start the engine. Wait 2 seconds.
    2.  
    3. Turn the ignition switch OFF and wait 10 seconds.
    4.  
    5. Turn the ignition switch ON, but do not start the engine.
    6.  
    7. Inspect for fuel leaks.
    8.  

  20.  
  21. Install the air cleaner outlet duct.
  22.  

 
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