Cruze

Fuel Injector and Fuel Rail Replacement

Special Tools

CH-807 Closure Plugs

Warning: Refer to Petrol/Petrol Vapours Warning in the Preface section.

Warning: Refer to Actions to Take When Working with Fuel Warning in the Preface section.

Warning: Refer to Safety Goggles and Fuel Warning in the Preface section.

Warning: Refer to Fuel Escape Warning in the Preface section.

1. Open the bonnet.
2. Remove the engine sight shield. Refer to Engine Sight Shield Replacement .
3. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
4. Disconnect the wiring harness from the fuel injectors.
5. Place a collecting basin underneath.
6. Disconnect the quick-release fitting of the fuel feed pipe. Refer to Plastic Collar Quick Connect Fitting Service .
7. Close the fuel feed pipe and the fuel rail with CH-807 plug.




Warning: Petrol or petrol vapours are highly flammable. A fire could occur if an ignition source is present. Never drain or store petrol or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.

8. Remove the 2 intake manifold bracket bolts (1).
9. Remove the 2 intake manifold bracket nuts (2).
10. Remove the intake manifold bracket (3).



11. Remove the 2 fuel injection fuel rail bolts (1).

Note: Be careful while removing. Do not damage the injectors.

12. Remove the fuel injection fuel rail (2).



13. Remove 4 retaining clamps (3).
14. Pull out the 4 injectors from the fuel injection fuel rail (1).

Note: Coat the seal rings with lubricant.

1. Install NEW injector seal rings.

Note: Inspect the installation position and ensure correct fitting.

2. Install the 4 injectors to the fuel injection fuel rail (1).
3. Install 4 retaining clamps (3).




Note: Be careful while Installing. Do not damage the injectors and injector seal rings.

4. Install the fuel injection fuel rail (2).

Caution: Refer to Fastener Caution in the Preface section.

5. Install the 2 fuel injection fuel rail bolts (1) and tighten to 25 N·m (18 lb ft).
6. Remove the CH-807 plugs.
7. Connect the quick-release fitting of the fuel feed pipe.
8. Connect the wiring harness to the fuel injectors.



9. Install the intake manifold bracket (3).
10. Install the 2 intake manifold bracket nuts (2) and tighten to 25 N·m (18 lb ft).
11. Install the 2 intake manifold bracket bolts (1) and tighten to 25 N·m (18 lb ft).
12. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
13. Install the engine sight shield. Refer to Engine Sight Shield Replacement .
14. Close the bonnet.