OEM 2004 Chevrolet Cavalier Fuel Rail

2004 Chevrolet Cavalier Parts Questions & Experts Answers

• Q: How to replace the fuel rail assembly on 2004 Chevrolet Cavalier?

  A: The first step for Fuel Rail assembly replacement requires you to drain fuel system pressure followed by removal of engine fuel supply and return pipes and air cleaner outlet resonator extraction and disconnecting the vent pipe from the Fuel Pressure Regulator. The procedure starts with removing the Fuel Pressure Regulator bolt followed by the Fuel Pressure Regulator. Then disconnect the Fuel Injector harness connectors while removing the Fuel Rail attaching studs. The technician should lift and pull the Fuel Rail while carefully detaching the fuel injectors from cylinder head ports before rotating the rail for downward position and finally removing it with attention to preserving both fuel injectors' electrical connector terminals and spray tips. Caretakers need to take out the fuel injectors once the Fuel Rail has been removed. New insulator cups must be installed on the fuel injectors before mounting them onto the Fuel Rail. To install the Fuel Rail begin by placing fuel injectors with the downward orientation before passing them into the cylinder head ports while rotating the rail forward to achieve alignment and finally pushing each injector carefully into position. New lower o-rings should be installed during Fuel Injector reuse while the injector tip o-rings require lubrication before installation occurs. Proceed with installing the Fuel Rail attaching studs and set their tightness at 10 n.m (89 lb in). You should connect the Fuel Injector harness connectors to a secure position before installing the fuel supply and return pipes and the Fuel Pressure Regulator and tightening the Fuel Pressure Regulator bolt to 10 n.m (89 lb in). The vent pipe should be connected to the Fuel Pressure Regulator while the air cleaner outlet resonator is installed along with a negative Battery Cable reconnection. To detect fuel leaks carefully turn on the ignition when the engine is off for two seconds followed by a ten-second shutdown period before checking for leakages with the ignition back on.