Removal instructions for fuel injection rail and injectors on 2005 chevy cavalier 2.2

Check for any trouble code, and make sure your security light is not on!

Do you have the black cover off the top of the engine? The fuel rail is on top of the engine. See parts breakout at link below. The sensor is on top of the rail between injectors 3 and 4. Chevrolet Malibu Injector Fuel injection Fuel injector rail 12633784...

remove the bolts that hold the fuel rail. Lift the fuel rail, pulling the injectors out carefully. Make sure the rubber seal comes out with the injector. Remove the electrical clip for the injectors you want to change. Clip in the new injector, and replace the fuel rail and the injectors.

un bolt the fuel rail. the injectors are pressed in for o rings are the seal for them and the pull right out

Remove the fuel rail along with the injectors attached to it. Remove the old seals. Clean the injector are very well with a solvent. Apply Vaseline to the seal mounting area on the injectors. Install the seals and coat them with Vaseline
Install the fuel rail and your done

Removal & Installation


Exploded view of the fuel rail and injector mounting


Take care when servicing the fuel rail assembly to prevent dirt or contaminants from entering the fuel system. ALL openings in the fuel lines and passages should be capped or plugged while disconnected.

1. Before disassembly, clean the fuel rail assembly with a spray type cleaner such as AC Delco® X-30A, or equivalent. After removal, DO NOT immerse the fuel rail in liquid solvent.
   
2. Properly relieve the fuel system pressure and disconnect the negative battery cable.
   
3. Remove the air intake duct, as necessary for access.
   
4. Tag and disengage the fuel injector electrical connectors.
   
5. Disengage the fuel pressure regulator vacuum line, then tag and disengage all other necessary vacuum hoses.
   
6. Loosen and remove the fuel rail retaining bolts.
   
7. If necessary to remove the fuel rail assembly completely from the engine compartment, or to prevent stressing and damaging the fuel lines, disconnect the fuel lines from the rail assembly.
   
8. Carefully lift the fuel rail assembly and fuel injectors from the intake.
   
9. Carefully release and separate the fuel injectors from the rail assembly.
   
10. Remove and discard ALL old O-rings from the fuel injectors and, if disconnected, the fuel lines.
    

To install:

1. Lightly coat the new O-rings with clean engine oil, then position them to the injectors and, if applicable, fuel fittings.
   
2. Install the injectors to the fuel rail assembly.
   
3. Carefully install the fuel rail and injectors to the intake manifold. Make sure the injectors are properly seated in their bores, but DO NOT force them into position.
   
4. Install and tighten the rail retaining bolts to 62 inch lbs. (7 Nm).
   
5. If removed, connect the fuel lines to the rail assembly and secure the fittings.
   
6. Engage the fuel pressure regulator and any other vacuum lines, as noted during removal.
   
7. Engage the injector electrical connectors.
   
8. Connect the negative battery cable and cycle the ignition switch (without attempting to start the engine) in order to pressurize the fuel system, then check for leaks.
   
9. Install the air intake duct.
   

Is the car fuel injected? you sure it doesn't have throttle body injection? if it is point injection you will see the silver fuel rail right on top of the engine, going into the head. If it's throttle body it will only have 1 injector on top of the carb(or throttle body).

There is a special tool for this it isn't expensive but it is the only way to safely make the change.

Also - remember to release the fuel line pressure before disconnecting the injector.

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Disconnect the negative battery cable.
Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.
Remove the air cleaner outlet resonator mounting screw.
Disconnect the air cleaner outlet resonator clamp at the throttle body.
Remove the air cleaner outlet duct from air cleaner outlet resonator and air cleaner assembly.
Disconnect the crankcase vent hose clamp and the crankcase vent hose from the top of the engine.
Remove the air cleaner outlet resonator.
Remove the fuel rail bracket.
Remove the fuel injector electrical connectors by pushing in the wire connector clip and pulling the electrical connector away from the fuel injector.
Remove the fuel feed inlet pipe quick connect.
Remove the fuel return pipe from the fuel pressure regulator.
Remove the fuel rail attaching bolts.
Remove the fuel rail assembly from the cylinder head.
Remove the fuel injector retaining clip.
Remove the fuel injector.
Important Visually inspect the fuel injector to see if the upper O-ring was also removed, if not, remove the O-ring from the fuel rail assembly

You will need to remove the fuel rail, pull the injector out and put new one in. Only thing you need to remember is that you have to pay attention to "o" ring seal, making sure you remove the old one and not damage the new one. There are specific instructions for removal in any inexpensive manual.