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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISENGINE PERFORMANCETESTING & DIAGNOSISENGINE CONTROLS - 2.4L - INTRODUCTION (2 OF 2)REPAIR INSTRUCTIONSFUEL RAIL ASSEMBLY REPLACEMENTREMOVAL PROCEDURE
2006 Chevrolet Cobalt SS, 4D Sedan, Standard

Removal Procedure

2006 Chevrolet Cobalt SS, 4D Sedan, StandardSECTION Removal Procedure
    Fig 1: Relieving Fuel System Pressure
    GM1647977Courtesy of GENERAL MOTORS CORP.
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  2. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  3. Disconnect the fuel feed line quick connect fitting (4) from the fuel rail. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
  4. Cap or plug the fuel line and the fuel rail to prevent contamination.
    5. Fig 2: Disconnecting Engine Harness Electrical Connector From Fuel Injector Harness
    GM1647528Courtesy of GENERAL MOTORS CORP.
  5. Disconnect the engine harness electrical connector (2) from the fuel injector harness.
  6. Remove the fuel injector harness connector clip from the intake manifold.
    7. Fig 3: Removing Fuel Rail Bolts
    GM1578472Courtesy of GENERAL MOTORS CORP.
  7. Remove the fuel rail bolts.
    8. IMPORTANT: Use care when removing the fuel rail assembly in order to prevent damage to the fuel injector electrical connector terminals and spray tips.
  8. Pull the fuel rail back and upward to remove the fuel injectors from the cylinder head ports.
  9. Remove the fuel rail.
  10. Remove the fuel injectors, if necessary. Refer to Fuel Injector Replacement .
RENDER: 1.0x

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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.