GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Optra - Mexico 🢒 Diagnostic Navigation 🢒 Vehicle Diagnostic Information 🢒 Fuel Injection Pump Replacement

Removal Procedure

    Object Number: 1820511 Size: SH

    Warning: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

  1. Remove the high pressure fuel pipes. Refer to Fuel Injector Fuel Feed Pipe Replacement.

    2. Object Number: 1820515 Size: SH
  2. Remove the intake manifold. Refer to Intake Manifold Replacement.
  3. Remove the timing belt. Refer to Timing Belt Replacement.
  4. Remove the power steering pump. Refer to Power Steering Pump Replacement.

    5. Object Number: 1820516 Size: SH

    Note: Put caps on the injection pump pipe connectors to avoid contamination from dust and dirt as soon as the fuel pipes are removed to prevent clogged the injectors.

  5. Remove the injection pump sprocket with the woodruff key.

    6. Object Number: 1820517 Size: SH
  6. Remove the injection pump assembly.

Installation Procedure

    Caution: Refer to Fastener Caution in the Preface section.


    Object Number: 1820517 Size: SH

    Caution: 

       • Use care when servicing the fuel system components, especially the fuel injector electrical connectors, the fuel injector tips, and the injector O-rings. Plug the inlet and the outlet ports of the fuel rail in order to prevent contamination.
       • Do not use compressed air to clean the fuel rail assembly as this may damage the fuel rail components.
       • Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to the fuel rail assembly.

    Important: Do not reuse the fuel pipes. If reused, the contaminated pipes may be damage the injectors or cause leaks from the pipes.

  1. Install the injection pump assembly.

    2. Tighten
    Tighten the injection pump bolts to 30 N·m (22.1 lb ft).

  2. Put the woodruff key groove of the injection pump drive shaft.
  3. Install the injection pump sprocket.
  4. Install the injection pump sprocket nut manually.

    5. Object Number: 1820518 Size: SH
  5. Align the sprocket mark on the timing belt rear cover mark.
  6. Install and align the timing belt. Refer to Timing Belt Replacement.
  7. Install the injection pump sprocket nut.

    8. Tighten
    Tighten the injection pump sprocket nut to 70 N·m (51.6 lb ft).


    Object Number: 1820516 Size: SH
  8. Prime the fuel system. Refer to Fuel System Priming.