GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2005 🢒 Matiz 🢒 Engine 🢒 Engine Controls - 1.0L 🢒 Fuel Injection Fuel Rail Assembly Replacement

Removal Procedure

    Notice: Refer to Fuel Pressure Notice in the Preface section.


    Object Number: 1240864 Size: SH
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  2. Remove the canister from the engine room. Refer to Evaporative Emission Canister Purge Solenoid Valve Replacement .
  3. Disconnect the fuel inlet line.
  4. Disconnect the fuel injector harness connectors.

    5. Object Number: 1240883 Size: SH

    Notice: 

       • 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.

  5. Remove the fuel rail bolts.
  6. Remove the fuel rail with the fuel injectors attached.

    7. Object Number: 1240885 Size: SH
  7. Remove the fuel injector retainer clips.
  8. Remove the fuel injectors from the fuel rail by pulling them down and out.

    9. Important: Different fuel 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 fuel injector.

  9. Discard the fuel injector O-rings.

Installation Procedure

    Caution: Refer to Safety Goggles and Fuel Caution in the Preface section.


    Object Number: 1240887 Size: SH

    Important: If a fuel injector becomes separated from the fuel rail and remains in the cylinder head, replace the fuel injector O-ring seals and the retaining clip.

  1. Lubricate the new fuel injector O-rings with engine oil. Install the new O-rings on the fuel injectors.
  2. Install the fuel injectors.
  3. Install the fuel injector retaining clips.

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

  4. Install the fuel rail retaining bolts.

    5. Tighten
    Tighten the fuel rail retaining bolts to 18-22 N·m (13-16 lb ft).


    Object Number: 1240882 Size: SH
  5. Connect the fuel injector harness connector.
  6. Connect the fuel inlet line.
  7. Install the evaporative emission canister.
  8. Perform a leak check of the fuel rail and the fuel injectors.