GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 Cobalt 🢒 Engine 🢒 Engine Controls and Fuel - 2.0L 🢒 High Pressure Fuel Pump Replacement

Removal Procedure

    Object Number: 2035275 Size: SH
  1. Relieve the low and high side fuel system pressure. Refer to Fuel Pressure Relief .
  2. Disconnect the engine wiring harness electrical connector (1) from the high pressure fuel pump.
  3. Remove the engine wiring harness clip (3) from the high pressure fuel pump cover.
  4. Remove the fuel feed intermediate pipe. Refer to Fuel Feed Intermediate Pipe Replacement .
  5. Remove the fuel feed pipe. Refer to Fuel Feed Pipe Replacement .

    6. Object Number: 1769960 Size: SH
  6. Remove and discard the high pressure fuel pump bolts.
  7. Remove the high pressure fuel pump.
  8. Remove and discard the high pressure fuel pump gasket.
  9. Remove and discard the high pressure fuel pump O-ring.

    10. Object Number: 1769961 Size: SH
  10. Remove the high pressure fuel pump roller lifter, if necessary.

Installation Procedure

    Object Number: 1769961 Size: SH
  1. Lubricate the high pressure fuel pump cylinder head bore and roller lifter with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent, if necessary.
  2. Install the high pressure fuel pump roller lifter, if necessary.

    3. Object Number: 1769960 Size: SH
  3. Install a NEW high pressure fuel pump O-ring.
  4. Position the NEW high pressure fuel pump gasket to the cylinder head.

    5. Important: Ensure the plastic bolt retainers are installed in the high pressure fuel pump mounting holes prior to installing.

  5. Install the high pressure fuel pump. Push the pump into the cylinder head bore by hand, applying force to the top of the pump.
  6. Install the NEW high pressure fuel pump bolts hand tight.
  7. Ensure that the high pressure fuel pump, and fuel rail fittings are clean prior to assembly.
  8. Lubricate the high pressure fuel pump, and the fuel rail fittings with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.

    9. Object Number: 2035280 Size: SH
  9. Install the NEW high pressure fuel pipe.
  10. Tighten the high pressure fuel pipe fitting to the fuel rail hand tight.
  11. Tighten the high pressure fuel pipe fitting to the fuel pump hand tight.

    12. Object Number: 2035279 Size: SH
  12. Place the fuel feed pipe onto the intake manifold.
  13. Install the fuel feed pipe bolts hand tight.

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

  14. Tighten the fuel feed pipe to fuel pump fitting hand tight.

    15. Tighten

    1. Tighten the fuel feed pipe bolts to 10 N·m (89 lb in).
    2. Tighten the fuel feed pipe to fuel pump fitting to 30 N·m (22 lb ft).
    3. Tighten the high pressure fuel pipe fittings to 32 N·m (24 lb ft).
    4. Tighten the high pressure fuel pump bolts evenly to 15 N·m (11 lb ft).

    Object Number: 2035277 Size: SH
  15. Install the high pressure fuel pump insulator.

    16. Object Number: 2035276 Size: SH
  16. Position the high pressure fuel pump cover.
  17. Install the high pressure fuel pump cover bolts.

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


    Object Number: 2035275 Size: SH
  18. Connect the engine wiring harness electrical connector (1) to the high pressure fuel pump.
  19. Install the engine wiring harness clip (3) to the fuel pump cover.
  20. Inspect for leaks using the following procedure:
    21. 20.1. Turn ON the ignition, with the engine OFF for 2 seconds.
    20.2. Turn OFF the ignition, for 10 seconds.
    20.3. Turn ON the ignition, with the engine OFF.
    20.4. Inspect for fuel leaks.
  21. Install the low side fuel pressure service port cap.
  22. Tighten the fuel fill cap.