GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Captiva Sport 🢒 Engine 🢒 Engine Mechanical - 2.4L 🢒 Fuel Injection Fuel Rail Assembly Replacement

Removal Procedure
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  4. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .

    5. Object Number: 1683133 Size: SH
  5. Disconnect the fuel feed line (1) quick connect fitting from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  6. Disconnect the engine wiring harness electrical connector from the manifold absolute pressure (MAP) sensor.
  7. Disconnect the fuel injector wiring harness electrical connector from the engine wiring harness electrical connector.

    8. Object Number: 1578472 Size: SH
  8. Remove the fuel injection fuel rail assembly bolts.

    9. Important: Use care when removing the fuel injection fuel rail assembly in order to prevent damage to the fuel injector spray tips.

  9. Pull the fuel injector fuel rail assembly back and upward in order to release the fuel injectors from the cylinder head ports.
  10. Remove the fuel injection fuel rail assembly.

    11. Object Number: 1336272 Size: SH

    Important: The fuel injector spray tips may be located on the fuel injectors or may still be located in the cylinder head ports. Either way, ensure that all 4 fuel injector spray tips are removed and discarded.

  11. Remove and discard the fuel injector spray tips.

    12. Object Number: 1683401 Size: SH
  12. Disconnect the fuel injector wiring harness electrical connectors from the fuel injectors.
  13. Remove the fuel injector wiring harness clips from the fuel injection fuel rail assembly.
  14. Remove the fuel injector wiring harness from the fuel injection fuel rail assembly.
  15. Remove the fuel injectors, if necessary. Refer to Fuel Injector Replacement .

Installation Procedure

    Important: If the fuel injection fuel rail assembly and fuel injectors were removed and re-installed without separating them then install NEW lower O-rings only. If the fuel injection fuel rail assembly was replaced then install NEW upper and lower O-rings.

  1. Install the fuel injectors, if necessary. Refer to Fuel Injector Replacement .

    2. Object Number: 1683401 Size: SH
  2. Install the fuel injector wiring harness to the fuel injection fuel rail assembly.
  3. Install the fuel injector wiring harness clips to the fuel injection fuel rail assembly.
  4. Connect the fuel injector wiring harness electrical connectors to the fuel injectors.

    5. Object Number: 1336272 Size: SH
  5. Lubricate the NEW fuel injector spray tips with clean engine oil.
  6. Install the NEW fuel injector spray tips to the cylinder head ports.
  7. Lubricate the fuel injector O-rings with clean engine oil.

    8. Object Number: 1578472 Size: SH
  8. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
  9. Carefully push down on the fuel injector fuel rail assembly in order to fully seat the fuel injectors into the cylinder head ports.

    10. Notice: Refer to Fastener Notice in the Preface section.

  10. Install the fuel injector fuel rail assembly bolts.

    11. Tighten
    Tighten the bolts to 10 N·m (89 lb in).

  11. Connect the fuel injector wiring harness electrical connector to the engine wiring harness electrical connector.
  12. Connect the engine wiring harness electrical connector to the manifold absolute pressure (MAP) sensor.

    13. Object Number: 1683133 Size: SH
  13. Connect the fuel feed line (1) quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  14. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .
  15. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  16. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  17. Inspect for fuel leaks using the following procedure:
    18. 17.1. Turn ON the ignition, with the engine OFF for 2 seconds.
    17.2. Turn OFF the ignition for 10 seconds.
    17.3. Turn ON the ignition.
    17.4. Inspect for fuel leaks.

Removal Procedure
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.
  2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
  4. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement.

    5. Object Number: 1683133 Size: SH
  5. Disconnect the fuel feed line (1) quick connect fitting from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service.
  6. Disconnect the engine wiring harness electrical connector from the manifold absolute pressure (MAP) sensor.
  7. Disconnect the fuel injector wiring harness electrical connector from the engine wiring harness electrical connector.

    8. Object Number: 1578472 Size: SH
  8. Remove the fuel injection fuel rail assembly bolts.

    9. Note: Use care when removing the fuel injection fuel rail assembly in order to prevent damage to the fuel injector spray tips.

  9. Pull the fuel injector fuel rail assembly back and upward in order to release the fuel injectors from the cylinder head ports.
  10. Remove the fuel injection fuel rail assembly.

    11. Object Number: 1336272 Size: SH

    Note: The fuel injector spray tips may be located on the fuel injectors or may still be located in the cylinder head ports. Either way, ensure that all 4 fuel injector spray tips are removed and discarded.

  11. Remove and discard the fuel injector spray tips.

    12. Object Number: 1683401 Size: SH
  12. Disconnect the fuel injector wiring harness electrical connectors from the fuel injectors.
  13. Remove the fuel injector wiring harness clips from the fuel injection fuel rail assembly.
  14. Remove the fuel injector wiring harness from the fuel injection fuel rail assembly.
  15. Remove the fuel injectors, if necessary. Refer to Fuel Injector Replacement.

Installation Procedure

    Note: If the fuel injection fuel rail assembly and fuel injectors were removed and re-installed without separating them then install NEW lower O-rings only. If the fuel injection fuel rail assembly was replaced then install NEW upper and lower O-rings.

  1. Install the fuel injectors, if necessary. Refer to Fuel Injector Replacement.

    2. Object Number: 1683401 Size: SH
  2. Install the fuel injector wiring harness to the fuel injection fuel rail assembly.
  3. Install the fuel injector wiring harness clips to the fuel injection fuel rail assembly.
  4. Connect the fuel injector wiring harness electrical connectors to the fuel injectors.

    5. Object Number: 1336272 Size: SH
  5. Lubricate the NEW fuel injector spray tips with clean engine oil.
  6. Install the NEW fuel injector spray tips to the cylinder head ports.
  7. Lubricate the fuel injector O-rings with clean engine oil.

    8. Object Number: 1578472 Size: SH
  8. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
  9. Carefully push down on the fuel injector fuel rail assembly in order to fully seat the fuel injectors into the cylinder head ports.

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

  10. Install the fuel injector fuel rail assembly bolts.

    11. Tighten
    Tighten the bolts to 10 N·m (89 lb in).

  11. Connect the fuel injector wiring harness electrical connector to the engine wiring harness electrical connector.
  12. Connect the engine wiring harness electrical connector to the manifold absolute pressure (MAP) sensor.

    13. Object Number: 1683133 Size: SH
  13. Connect the fuel feed line (1) quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service.
  14. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement.
  15. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
  16. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  17. Inspect for fuel leaks using the following procedure:
    18. 17.1. Turn ON the ignition, with the engine OFF for 2 seconds.
    17.2. Turn OFF the ignition for 10 seconds.
    17.3. Turn ON the ignition.
    17.4. Inspect for fuel leaks.