2005 Pontiac Aztek Base, FWDFACTORY OEM SERVICE PROCEDURE

Installation Procedure

CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always install the fuel injector O-rings in the proper position. If the upper and lower O-rings are different colors (black and brown), be sure to install the black O-ring in the upper position and the brown O-ring in the lower position on the fuel injector. The O-rings are the same size but are made of different materials.
  1. If you are replacing the fuel rail, install the fuel injectors to the fuel rail. Refer to Fuel Injector Replacement  in Engine Controls.
  2. Install the fuel injector O-rings using GM P/N 12345616, (Canadian P/N 993182) or the equivalent.
  3. Carefully install the fuel rail with the fuel injectors to the lower intake manifold.
  4. Ensure that the nozzle ends of each fuel injector are located properly in the injector bores.
    5. IMPORTANT: Do not press on the fuel pressure regulator valve when installing the fuel injector rail assembly.
  5. Press on the injector rail using the palms of both hands until the fuel injectors are fully seated.
    6. NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Install the fuel rail bolts.

    Tighten:  Tighten the fuel rail attaching bolt to 10 N.m (89 lb in).

    7. Fig 1: View Of ECT Sensor, Connector And Wiring Harness At Fuel Rail
    GM15986Courtesy of GENERAL MOTORS CORP.
  7. Connect the coolant temperature sensor electrical connector.
  8. Install the injector electrical harness to the fuel rail.
  9. Apply grease GM P/N 12377900 (Canadian P/N 10953529) or equivalent to the fuel injector electrical connectors.
    10. Fig 2: Identifying Lock Release
    GM372749Courtesy of GENERAL MOTORS CORP.
  10. Install the fuel injector electrical connectors to the fuel injectors.
  11. Push the slide locks (2) into position.
  12. Connect the fuel injector harness main electrical connector.
  13. Install new O-rings to the fuel feed pipe and fuel return pipe.
    14. Fig 3: Identifying Engine Fuel Feed Pipe
    GM22505Courtesy of GENERAL MOTORS CORP.
  14. Connect the fuel feed pipe to the fuel rail.

    Tighten:  Tighten the fuel feed pipe nut to 17 N.m (13 lb ft).

    15. Fig 4: View Of Fuel Return Pipe
    GM22507Courtesy of GENERAL MOTORS CORP.
  15. Connect the fuel return pipe to the fuel pressure regulator.

    Tighten:  Tighten the fuel return pipe nut to 17 N.m (13 lb ft).

  16. Install the upper intake manifold. Refer to Intake Manifold Replacement - Upper in Engine Mechanical.
  17. Inspect for fuel leaks with the following procedure:
    1. Turn the ignition ON for 2 seconds.
    2. Turn the ignition OFF for 10 seconds.
    3. Turn the ignition ON.
    4. Inspect for fuel leaks.
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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