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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 656 (ENGINE CONTROLS AND FUEL - 2.0L - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSFUEL INJECTION FUEL RAIL ASSEMBLY REPLACEMENTINSTALLATION PROCEDURE
2006 Chevrolet Cobalt SS, 4D Sedan, Standard

Installation Procedure

2006 Chevrolet Cobalt SS, 4D Sedan, StandardSECTION Installation Procedure
WARNING: This page is about a different car, the 2008 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Fuel Rail Fuel Pressure Sensor
    GM1829977Courtesy of GENERAL MOTORS CORP.
  1. If the fuel rail was replaced, Lubricate the threads and sealing cone of the NEW fuel rail with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
  2. Lubricate the threads and sealing cone of the sensor with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
    IMPORTANT: Applying force to the plastic housing of the sensor will destroy the sensor. To tighten or loosen, only apply force to the attached hexagon.
    3. NOTE: Refer to Fastener Notice .
  3. Install the fuel injection fuel rail fuel pressure sensor.

    Tighten:  Tighten the sensor to 33 N.m (25 lb ft).

  4. Install the fuel injector wiring harness.
    5. Fig 2: View Of Fuel Injector Components
    GM1829979Courtesy of GENERAL MOTORS CORP.
  5. Install a NEW plastic spacer (2) if the old one was damaged.
  6. Lubricate a NEW fuel injector upper O-ring seal (1) with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
  7. Install the NEW fuel injector upper O-ring seal (1).
    8. Fig 3: View Of Fuel Rail & Bolts
    GM1829953Courtesy of GENERAL MOTORS CORP.
  8. Place the fuel rail (2) into position.
  9. Install the 2 outer fuel rail bolts (1) first hand tight, and then install the remaining 2 bolts, hand tight.
  10. Connect the fuel injector wiring harness electrical connectors to the fuel injectors.
    11. Fig 4: Identifying Fuel Rail Bolt Tightening Sequence
    GM1769965Courtesy of GENERAL MOTORS CORP.
  11. Tighten the fuel rail bolts in the sequence shown.

    Tighten: 

    • Tighten the bolts a first pass to 22 N.m (16 lb ft).
    • Tighten the bolts a final pass to 22 N.m (16 lb ft).

  12. Install the intermediate fuel pipe. Refer to Fuel Feed Intermediate Pipe Replacement .
    13. Fig 5: View Of Engine Wiring Harness Connector & High Pressure Fuel Pump
    GM1826282Courtesy of GENERAL MOTORS CORP.
  13. Connect the engine wiring harness electrical connector (1) to the high pressure fuel pump.
    14. Fig 6: View Of Fuel Injector Insulator
    GM1769947Courtesy of GENERAL MOTORS CORP.
  14. Install the fuel injector insulator.
  15. Install the intake manifold. Refer to Intake Manifold Replacement .
    16. Fig 7: View Of Engine Wiring Harness Connector & Fuel Injector Wiring Harness Connector
    GM1826857Courtesy of GENERAL MOTORS CORP.
  16. Connect the engine wiring harness electrical connector (1) to the fuel injector wiring harness electrical connector.
  17. Inspect for leaks using the following procedure:
    1. Turn ON the ignition, with the engine OFF for 2 seconds.
    2. Turn OFF the ignition, for 10 seconds.
    3. Turn ON the ignition, with the engine OFF.
    4. Inspect for fuel leaks.
  18. Install the low side fuel pressure service port cap.
  19. Tighten the fuel fill cap.
  20. Install the air cleaner assembly. Refer to Air Cleaner Assembly 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.