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HOMESERVICE MANUALSCHEVROLET2001CAVALIER LS, 2.4 TREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 66 (ENGINE CONTROLS - REMOVAL & INSTALLATION)FUEL SYSTEMS (GASOLINE)FUEL RAIL & INJECTORSINSTALLATION
2001 Chevrolet Cavalier LS, 2.4 T

Fuel Rail & Injectors: Installation

2001 Chevrolet Cavalier LS, 2.4 TSECTION Installation
WARNING: This page is about a different car, the 2003 Pontiac Sunfire and 2003 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. If the fuel injector insulator cups are removed from the cylinder head while removing the fuel rail, NEW insulator cups must be installed. See Figure.
    2. NOTE: Always install NEW injector "O" rings when servicing the fuel injectors. Lubricate the NEW injector "O" rings with clean engine oil.
  2. Install the "O" rings on the fuel injector.
  3. Install the fuel injectors to the fuel rail.
  4. Install the fuel injector clip. See Figure.
  5. Install the fuel injector harness connector.
  6. Install the fuel rail using the following procedure:
    • With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
    • Align the injectors by rotating the fuel rail forward.
    • Carefully push the fuel injectors into the cylinder head ports.
  7. Install the fuel rail attaching studs. See Figure. Tighten the fuel rail studs to specification. See TORQUE SPECIFICATIONS .
  8. Connect the fuel injector harness connectors. Pull back on connector to insure the connectors are locked in place.
  9. Install the fuel supply and return pipes.
  10. Install the fuel pressure regulator. See Figure.
  11. Install the fuel pressure regulator bolt. Tighten the fuel pressure regulator bolt to specification. See TORQUE SPECIFICATIONS .
  12. Connect the vent pipe to the fuel pressure regulator. See Figure.
  13. Install the air cleaner outlet resonator.
  14. Connect the negative battery cable. Tighten to specification. See TORQUE SPECIFICATIONS .
  15. Check for fuel leaks using the following procedure:
    • Turn ignition switch to RUN position for 2 seconds.
    • Turn ignition switch to OFF position for 10 seconds.
    • Turn ignition switch to RUN position.
    • Check for fuel leaks.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.