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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 839 (ENGINE CONTROLS AND FUEL - 2.0L - REPAIR INSTRUCTIONS)REPAIR INSTRUCTIONSDIRECT FUEL INJECTOR 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 2010 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Fuel Rail Bolt Tightening Sequence
    GM1769965Courtesy of GENERAL MOTORS CORP.
  1. Install the 2 outer fuel rail bolts (1) first, hand tight and install the remaining 2 bolts, hand tight.
  2. Connect the fuel injector wiring harness electrical connectors to the fuel injectors.
    3. CAUTION: Refer to Fastener Caution .
  3. Tighten the fuel rail bolts in the sequence shown.
    1. Tighten the bolts a first pass to 22 N.m (16 lb ft).
    2. Tighten the bolts a final pass to 22 N.m (16 lb ft).
  4. Install the fuel feed intermediate pipe. Refer to Fuel Feed Intermediate Pipe Replacement .
    5. Fig 2: View Of Engine Wiring Harness & High Pressure Fuel Pump
    GM2035275Courtesy of GENERAL MOTORS CORP.
  5. Connect the engine wiring harness electrical connector (1) to the high pressure fuel pump.
  6. Install the engine wiring harness clip (3) to the high pressure fuel pump cover.
    7. Fig 3: Fuel Injector Insulator
    GM1769947Courtesy of GENERAL MOTORS CORP.
  7. Install the fuel injector insulator.
    8. Fig 4: Identifying Engine Wiring Harness Connector & Fuel Injector Wiring Harness Connector
    GM2035304Courtesy of GENERAL MOTORS CORP.
  8. Connect the engine wiring harness electrical connector (1) to the fuel injector wiring harness electrical connector.
  9. 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.
  10. Install the low side fuel pressure service port cap.
  11. Tighten the fuel fill cap.
  12. Install the intake manifold assembly. Refer to Intake Manifold 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.