NOTE: When fuel rail is removed for service, fuel injectors must be
removed and all injector "O" rings must be replaced.
Removal (2.2L - Saturn)
1) Relieve fuel pressure. See
FUEL SYSTEM PRESSURE RELEASE (GASOLINE). Disconnect negative battery
cable. Remove air intake tube and fresh air tube. Disconnect fuel
pressure regulator hose from throttle body and fuel rail. Disconnect
fuel supply line and discard plastic retainer.
2) Remove throttle body. Remove throttle control cable
bracket bolts. Disconnect cable from throttle lever and lay over
intake manifold. Disconnect fuel injector electrical connectors.
Remove fuel rail assembly mounting bolts. Carefully pull fuel rail
back and upward to remove injectors from cylinder head ports. See
Fig. 16.
3) Move fuel rail toward power steering pump and rotate
injectors downward. Lift No. 1 injector and remove fuel rail. Remove
fuel injector retaining clips and pull injectors from fuel rail.
Remove injector "O" rings and discard.
Installation
1) Install NEW "O" rings lubricated with clean engine oil
onto each injector. Install injectors onto fuel rail. With injectors
pointing downward, lower fuel line end of fuel rail into cylinder head
ports. Rotate injectors into horizontal position and align injectors
with cylinder head ports.
2) Carefully push fuel injectors into cylinder head ports,
ensuring they fully seat into cylinder head. Install fuel rail
mounting bolts and tighten to specification. See TORQUE SPECIFICATIONS
. To complete installation, reverse removal procedure using NEW fuel
supply line plastic retainers.
Removal (2.4L)
1) Relieve fuel pressure. See
FUEL SYSTEM PRESSURE RELEASE (GASOLINE). Disconnect negative battery
cable. Remove air cleaner outlet duct clamp. Remove air cleaner outlet
duct from air cleaner resonator. Loosen air cleaner resonator clamp at
throttle body. Remove resonator retaining bolts and nuts. Lift air
cleaner resonator from throttle body.
2) Remove crankcase vent hose to bottom of resonator. Remove
resonator. Disconnect vacuum hose at pressure regulator. Remove fuel
rail attaching bolts. Disconnect camshaft position sensor harness
connector. Push in on injector connector clip and disconnect harness
connectors from injectors.
3) Using a wrench to hold fuel inlet fitting, disconnect and
plug fuel inlet line at fuel rail. Lift fuel rail assembly from
cylinder head. Loosen fuel return pipe retaining bracket screw. Rotate
retaining bracket for removal of fuel return pipe. Remove fuel return
pipe from pressure regulator.
4) Remove inlet and return pipe to fuel feed and return line
connections. Remove inlet and return pipe assemblies and discard "O"
rings. Remove fuel rail assembly. See Fig. 18. Remove injector-to-fuel
rail retaining clip. Remove injector from fuel rail. Remove injector
"O" rings and discard.
Installation
To install, reverse removal procedure. Lubricate NEW injector
"O" rings with clean engine oil. Position injectors into fuel rail and
install retaining clips. Install NEW injector-to-fuel rail retaining
clip with open end facing injector harness connection. Tighten fuel
rail retaining bolts. See TORQUE SPECIFICATIONS. To complete
installation, reverse removal procedure.
