GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2004 🢒 ION 🢒 Engine 🢒 Engine Electrical 🢒 Fuel Injection Fuel Rail Assembly Replacement

Removal Procedure
  1. Remove the coolant overflow pipe.

    2. Object Number: 1381514 Size: SH
  2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  3. Use a back up wrench on the fuel rail and disconnect the fuel supply pipe.
  4. Remove the fuel rail attaching studs.

    5. Important: Use care when removing the fuel rail assembly in order to prevent damage to the fuel injectors electrical connector terminals and spray tips.

  5. Remove the fuel rail using the following procedure:
    6. 5.1. Pull the fuel rail back and upward to remove the fuel injectors from the cylinder head ports.
    5.2. Rotate the fuel rail in order to position the injectors downward.
    5.3. Remove the fuel rail.
  6. Disconnect the fuel injector harness connectors.
  7. Remove the fuel injectors. Refer to Fuel Injector Replacement .

Installation Procedure

    Object Number: 1381514 Size: SH
  1. Install the fuel injectors. Refer to Fuel Injector Replacement .
  2. Connect the fuel injector harness connectors. Pull back to insure the connectors are locked in place.

    3. Important: Install new lower O-rings when reusing fuel injectors. Lubricate the injector tip O-rings prior to installing the injectors into the intake manifold.

  3. Install the fuel rail using the following procedure:
    4. 3.1. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
    3.2. Align the injectors by rotating the fuel rail forward.
    3.3. Carefully push the fuel injectors into the cylinder head ports.

    Notice: Refer to Fastener Notice in the Preface section.

  4. Install the fuel rail attaching studs.

    5. Tighten
    Tighten the fuel rail studs to 10 N·m (89 lb in).

  5. Install the fuel supply pipe.

    6. Tighten
    Using a backup wrench on the fuel rail tighten the fuel supply pipe to 22 N·m (16 lb ft).

  6. Install the coolant overflow pipe.

    7. Tighten
    Tighten the pipe bolt to 8 N·m (71 lb in).

  7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  8. Inspect for fuel leaks using the following procedure:
    9. 8.1. Turn ON the ignition, with the engine OFF for 2 seconds.
    8.2. Turn OFF the ignition for 10 seconds.
    8.3. Turn ON the ignition.
    8.4. Inspect for fuel leaks.