GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Aveo 🢒 Engine 🢒 Engine Electrical 🢒 Fuel Injection Fuel Rail Assembly Replacement

Removal Procedure

    Warning: Refer to Battery Disconnect Warning in the Preface section.

  1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.

    2. Caution: Refer to Fuel Pressure Caution in the Preface section.

  2. Relieve the fuel pressure. Refer to Fuel Pressure Relief.
  3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
  4. Disconnect the quick connector fuel feed line from the fuel rail.
  5. Disconnect the wiring harness from the upper side of the fuel rail.
  6. Disconnect the fuel injector harness connector.
  7. Remove the fuel rail mounting bolts.
  8. Remove the fuel rail with the fuel injectors attached.

    9. Object Number: 2042519 Size: SH
  9. Remove the fuel injector retainer clips (3).
  10. Remove the fuel injectors (2) by pulling down and out.
  11. Discard the fuel injector O-rings.

Installation Procedure

    Object Number: 2042519 Size: SH

    Note: Different injectors are calibrated for different flow rates. When ordering new fuel injectors, be certain to order the identical part number that is inscribed on the old injector.

  1. Install the new O-rings on the fuel injectors (2).
  2. Install the retainer clip (3) after installing injectors on the fuel rail (1).
  3. Install the fuel rail and injector assembly to the intake manifold.

    4. Caution: Refer to Fastener Caution in the Preface section.

  4. Install the fuel rail retaining bolts and tighten to 10 N·m (7.3 lb ft).
  5. Connect the fuel injector harness connectors.
  6. Connect the harness on the upper side of the fuel rail.
  7. Connect the quick connector fuel feed line on the fuel rail.
  8. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement
  9. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.