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Home >> Pontiac >> 2005 >> Sunfire Automatic >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - 2.2L - Introduction >> Repair Instructions >> Fuel Rail Assembly Replacement >> Installation Procedure
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Installation Procedure

    Fig 1: Identifying Fuel Injector Insulator Cups
    GM894737Courtesy of GENERAL MOTORS CORP.
  1. If the fuel injector insulator cups (1) are removed from the cylinder head while removing the fuel rail, new insulator cups must be installed.
  2. Install the fuel injectors to the fuel rail. Refer to Fuel Injector Replacement .
    3. Fig 2: Locating Fuel Rail Attaching Studs
    GM870600Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Install new lower O-rings when reusing fuel injectors. Lubricate the injector tip O-rings prior to installing the injectors into the intake manifold.
  3. Install the fuel rail using the following procedure:
    1. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
    2. Align the injectors by rotating the fuel rail forward.
    3. Carefully push the fuel injectors into the cylinder head ports.
    4. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the fuel rail attaching studs (1).

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

    5. Fig 3: View Of Fuel Injector Harness Connectors
    GM870618Courtesy of GENERAL MOTORS CORP.
  5. Connect the fuel injector harness connectors. Pull back to insure the connectors are locked in place.
  6. Install the fuel supply and return pipes. Refer to Fuel Hose/Pipes Replacement - Engine Compartment .
    7. Fig 4: Identifying Fuel Pressure Regulator
    GM870630Courtesy of GENERAL MOTORS CORP.
  7. Install the fuel pressure regulator.
    8. Fig 5: Locating Fuel Pressure Regulator Retaining Bolt
    GM870632Courtesy of GENERAL MOTORS CORP.
  8. Install the fuel pressure regulator bolt (1).

    Tighten:  Tighten the fuel pressure regulator bolt to 10 N.m (89 lb in).

    9. Fig 6: View Of Fuel Pressure Regulator Vent Pipe
    GM870490Courtesy of GENERAL MOTORS CORP.
  9. Connect the vent pipe to the fuel pressure regulator.
  10. Install the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement .
  11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  12. 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.
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