Cavalier/Z24 L4-144 2.4L DOHC VIN T SFI (1996)
locking.
1. Whenever the fuel rail is disconnected from fuel pipes, reconnect fuel pipes to rail at this time.
2. Install the return pipe into regulator (11).
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(Align bracket to retain return pipe).
Tighten
Return pipe bracket screw (7) to 6.0 Nm (53 lb. in.).
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Use a backup wrench on the fitting to prevent it from turning.
Fuel inlet pipe nut to 30 Nm (22 lb. ft.).
Important: Rotate fuel injector(3) as required to avoid stretching the wire harness.
3. Position fuel rail (1) over cylinder head and connect fuel injector electrical connectors.
4. Install the fuel rail assembly into cylinder head.
5. Install the fuel rail assembly attaching bolts.
Tighten
Bolts to 26 Nm (19 lb. ft.).
6. Install the vacuum hose to fuel pressure regulator (11).
7. If front (engine) fuel pipes are being replaced, install new fuel pipe O-rings (9), coated with clean engine oil.
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Use a backup wrench to prevent female fitting from turning.
8. Install the inlet and return pipe connections.
Tighten
Fittings to 27 Nm (20 lb. ft.).
9. Install the fuel pipe clamp bolt.
Tighten
Bolt to 12 Nm (106 lb. in.).
Important: Apply a few drops of clean engine oil to the vent hose and the air cleaner resonator before installing.
10. Install the crankcase vent hose to bottom of the air cleaner resonator.
11. Install the air cleaner resonator (2) to throttle body (3).
Tighten
Clamp to throttle body 4-5 Nm (35-44 lb. in.).
12. Install the air cleaner resonator attaching bolts (1).
Tighten
Bolts to 10 Nm (89 lb. in.).
13. Air cleaner outlet duct to air cleaner resonator.
Tighten
Clamp to 4-5 Nm (35-44 lb. in.).
14. Install the negative battery cable.
15. Inspect for fuel leaks through the following steps:
1. Turn the ignition switch to the ON position for two seconds.
2. Turn the ignition switch to the OFF position for ten seconds.
3. Turn the ignition switch to the ON position.
4. Check for fuel leaks.
