Replacing Fuel Injectors In Chevrolet Aveo: Step-By-Step Guide

If you notice smoke coming from your Chevrolet Aveo's tailpipe, a reduction in fuel efficiency, or a strong smell of fuel, you may need to replace your fuel injectors. This is not a DIY job, as there is a risk of fire and the process can be complicated. The average cost for a Chevrolet Aveo Fuel Injector replacement is $582, with $442 for parts and $140 for labor.

Removing the intake manifold

To remove the intake manifold of a 2009 Chevrolet Aveo, you must first relieve the pressure within the fuel rail. This can be done by briefly running the engine with the fuel pump fuse removed. Next, remove the upper plenum on the intake manifold, along with any cables, hoses, or wiring that may restrict access. Then, remove the supply and return lines from the fuel rail, and disconnect the electrical connectors from each fuel injector. The fuel rail can now be unbolted and removed from the intake manifold.

It is important to note that this process can be complex and, if done incorrectly, can cause further damage to the vehicle. It is recommended that fuel injector replacement be left to a professional.

Disconnecting the fuel injector

• Ensure the engine is cold. Briefly run the engine with the fuel pump fuse out to relieve the pressure within the fuel rail.
• Remove the upper plenum on the intake manifold, along with any cables, hoses, or wiring that restricts access.
• Disconnect the supply and return lines from the fuel rail.
• Unlock and remove the electrical connectors from each fuel injector.
• Unbolt and remove the fuel rail from the intake manifold.
• Remove the injector(s) requiring replacement from the fuel rail, being careful not to allow any debris to enter the exposed openings. An O-ring seal usually holds the injector very firmly in a finely polished bore in the fuel rail.
• Re-insert the serviced or replaced injector(s) into the fuel rail, using a new O-ring and engine oil to prevent damage to the O-ring.
• Re-install the fuel rail, and re-connect the supply and return lines.
• Re-install the plenum, along with all cables, hoses, or wiring.
• Run the engine and check carefully for leaks.
• Finally, road test the vehicle.

Installing a new fuel injector

Step 1: Prepare the Engine

Before you begin, ensure the engine is cold. Then, relieve the pressure within the fuel rail by briefly running the engine with the fuel pump fuse removed. This is an important safety precaution.

Step 2: Remove the Upper Plenum and any Restrictive Cables, Hoses, or Wiring

Remove the upper plenum on the intake manifold, as well as any cables, hoses, or wiring that may restrict access to the fuel injectors.

Step 3: Disconnect the Fuel Rail

Remove the supply and return lines from the fuel rail. Then, disconnect the electrical connectors from each fuel injector and unbolt the fuel rail from the intake manifold.

Step 4: Remove the Old Fuel Injector

Carefully remove the fuel injector requiring replacement from the fuel rail. Be extremely cautious not to let any debris enter the exposed openings. Typically, an O-ring seal holds the injector in place, so you may need to use a tool to carefully remove it without causing damage.

Step 5: Install the New Fuel Injector

Take your new fuel injector and, using engine oil, lubricate a new O-ring before inserting the injector into the fuel rail. Ensure that the O-ring is not damaged during this process. O-rings in this application fit very tightly to prevent fuel leaks, so take care when inserting the new injector.

Step 6: Re-install the Fuel Rail and Reconnect the Supply and Return Lines

Once the new injector is in place, re-install the fuel rail and reconnect the supply and return lines.

Step 7: Re-install the Upper Plenum and any Other Components

Finally, re-install the upper plenum, as well as any cables, hoses, or wiring that were removed earlier.

Step 8: Test the Vehicle

Start the engine and carefully check for leaks. Then, take the vehicle for a road test to ensure the new fuel injector is functioning correctly.

It is important to note that fuel injector replacement can be a complex process and it is recommended that it be left to a professional. If you are not confident in your ability to perform the replacement, do not hesitate to consult a qualified mechanic.

Re-installing the fuel rail

Firstly, ensure the engine is cold. This is important as you will need to briefly run the engine with the fuel pump fuse removed to relieve the pressure within the fuel rail.

Now, re-install the fuel rail onto the intake manifold, using bolts to secure it in place. Next, reconnect the supply and return lines to the fuel rail.

Then, reconnect the electrical connectors to each fuel injector. The fuel injectors should be locked into place within the fuel rail. Ensure the O-ring seals are fitted correctly, as these prevent fuel leaks.

Finally, re-install the upper plenum on the intake manifold, along with any cables, hoses, or wiring that were removed to access the fuel rail.

Checking for leaks

Firstly, it is important to note that if there is an external leak of fuel from a broken or malfunctioning injector, do not start the car due to the risk of fire. If there is no external leak, the engine can be briefly run with the fuel pump fuse removed to relieve the pressure within the fuel rail.

Next, remove the upper plenum on the intake manifold, as well as any cables, hoses, or wiring that may restrict access to the fuel injectors. Once you have clear access, the supply and return lines can be removed from the fuel rail, and the electrical connectors to each fuel injector can be unlocked and removed.

At this point, the fuel rail can be unbolted and removed from the intake manifold. Check the injector(s) requiring replacement for any signs of leaks or damage. Take care not to allow any debris to enter the exposed openings.

When you are happy that there are no leaks, and the faulty injector(s) have been replaced, the fuel rail can be re-installed, and the supply and return lines re-connected. The plenum and any cables, hoses, or wiring can then be re-installed.

Finally, the engine can be run and a careful check for leaks can be performed. The vehicle should then be road-tested to ensure that there are no leaks and that the problem has been fixed.

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