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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 840 (ENGINE CONTROLS AND FUEL - 2.2L - REPAIR INSTRUCTIONS)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 2010 Pontiac G5 and 2010 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Install NEW lower O-rings when reusing fuel injectors. Lubricate the injector tip O-rings prior to installing the injectors into the intake manifold.
    Fig 1: View Of Fuel Rail
    GM1578472Courtesy of GENERAL MOTORS CORP.
  1. Remove the fuel injectors, if necessary. Refer to Fuel Injector Replacement .
  2. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
  3. Carefully push the fuel injectors into the cylinder head ports.
    4. CAUTION: Refer to Fastener Caution .
  4. Install the fuel rail bolts and tighten to 10 N.m (89 lb in).
    5. Fig 2: Identifying Engine Harness Electrical Connectors
    GM1647528Courtesy of GENERAL MOTORS CORP.
  5. Connect the engine harness electrical connector (1) to the MAP sensor.
  6. Connect the engine harness electrical connector (2) to the fuel injector harness.
  7. Install the fuel injector harness connector clip to the intake manifold.
    8. Fig 3: Identifying Fuel Line
    GM1647977Courtesy of GENERAL MOTORS CORP.
  8. Remove the caps or plugs from the fuel line and the fuel rail.
  9. Connect the fuel feed line quick connect fitting (4) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  11. Inspect for fuel 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.
    4. Inspect for fuel leaks.
  12. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct 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.