GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2000 🢒 Cavalier 🢒 Engine 🢒 Engine Controls - 2.4L 🢒 Fuel Injection Fuel Rail Assembly Replacement

Removal Procedure

    Object Number: 399065 Size: SH
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  2. Remove air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement .
  3. Disconnect the quick-connect fittings at the engine compartment fuel feed and return connecting lines. Refer to Metal Collar Quick Connect Fitting Service .
  4. Plug fuel lines.
  5. Remove the engine fuel line hold-down retaining bolts.
  6. Disconnect CMP sensor electrical connector.
  7. Disconnect fuel injector electrical connectors.
  8. Disconnect vacuum hose from the fuel pressure regulator.
  9. Remove the fuel feed pipe from the fuel rail using a back-up wrench.
  10. Remove fuel rail retaining bolts.
  11. Remove fuel rail from engine with return line attached.
  12. Remove fuel return line retaining bolt(4) and retainer(5).
  13. Remove fuel return line from fuel pressure regulator(1).
  14. Remove fuel pressure regulator retaining bolt(8).
  15. Remove fuel pressure regulator(1)
  16. Discard O-rings.

Installation Procedure

    Object Number: 399065 Size: SH
  1. Lubricate new rail to regulator inlet O-ring seal (3) with clean engine oil and install in the fuel pressure regulator.
  2. Install fuel pressure regulator.

    3. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

    Important: If the fuel pressure regulator is to be re-installed, inspect filter screen (2) for contamination. If contaminated remove and discard filter screen.

    Important: Whenever there is not enough thread-lock material on the threads of reusable hardware, apply Loctite® 262 to ensure proper locking.

  3. Install fuel pressure regulator bolt.

    4. Tighten
    Tighten the fuel pressure regulator bolt to 6 N·m 53 lb in.

  4. Lubricate new return line to regulator O-ring seal (7) with clean engine oil and install on fuel return line.
  5. Install fuel return line into fuel pressure regulator.
  6. Install fuel return line bolt and retainer.

    7. Tighten
    Tighten the fuel return line bolt to 12 N·m 106 lb in.

  7. Install the fuel rail assembly on engine.
  8. Install fuel rail retaining bolts.

    9. Tighten
    Tighten fuel rail retaining bolts to 24 N·m 18 lb ft.

  9. Install fuel feed pipe to fuel rail using a back-up wrench.

    10. Tighten
    Tighten the fuel feed pipe line nut to 30 N·m 22 lb ft.

  10. Connect vacuum line to fuel pressure regulator.
  11. Connect fuel injector electrical connectors.
  12. Connect CMP sensor electrical connector.
  13. Reinstall the engine fuel line hold-down retainer and bolts.

    14. Tighten
    Tighten fuel line hold-down bolts to 12 N·m 106 lb in.

  14. Unplug fuel lines.
  15. Reconnect quick connect fittings at the engine compartment fuel feed and return connecting lines. Refer to Fuel Pressure Relief .
  16. Install air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement
  17. Install negative battery cable.
  18. Inspect for fuel leaks through the following steps.
    19. 18.1. Turn the ignition switch to the ON position for two seconds.
    18.2. Turn the ignition switch to the OFF position for ten seconds.
    18.3. Turn the ignition switch to the ON position.
    18.4. Check for fuel leaks.