2004 Chevrolet Tracker RWDFACTORY OEM SERVICE PROCEDURE

Installation Procedure

    IMPORTANT: Always replace the fuel injector O-rings with new O-rings when servicing the fuel injectors. Do not damage the O-rings during the installation.
  1. Apply a thin coat of motor oil to the fuel injector O-rings (1).
  2. Install a fuel injector O-ring (1) with a spacer (2) to each fuel injector (3).
  3. Install each fuel injector (3) to the fuel rail.
  4. Apply a thin coat of motor oil to the fuel pressure regulator O-ring.
    5. NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Install the fuel pressure regulator (5) to the left fuel rail and secure with two bolts.

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

    6. IMPORTANT: Inspect the fuel injector cushions for scoring or for damage. Before installing the fuel injectors to the intake manifold, replace any faulty injector cushions.
  6. Prepare each fuel rail assembly for installation to the intake manifold, by ensuring that a cushion (4) is present in the seat location of each fuel injector. Replace any missing or damaged cushions as necessary.
    7. Fig 1: View Of Fuel Injectors, O-Rings, Spacer & Fuel Pressure Regulator
    GM675888Courtesy of GENERAL MOTORS CORP.
  7. Install the left fuel rail to the intake manifold with two bolts and two spacers (1).

    Tighten:  Tighten the bolts to 23 N.m (16.5 lb ft).

  8. Install the right fuel rail to the intake manifold with two bolts and two spacers (1).

    Tighten:  Tighten the bolts to 23 N.m (16.5 lb ft).

    9. Fig 2: View Of Left Fuel Rail & Intake Manifold Bolts
    GM675884Courtesy of GENERAL MOTORS CORP.
Factory Service Tools

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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.

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