GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2002 🢒 Sunfire 🢒 Engine 🢒 Engine Controls - 2.2L (LN2) 🢒 Fuel Injection Fuel Rail Assembly Replacement

Removal Procedure

    Object Number: 143272 Size: SH
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  2. Remove the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement .
  3. Remove the air cleaner resonator bracket (1).
  4. Disconnect the vacuum hose from the fuel pressure regulator.

    5. Object Number: 372749 Size: SH
  5. Pull up the lock release (2) of the fuel injector connector.

    6. Object Number: 372753 Size: SH
  6. Depress the lock tab (1) and lift the connector from the injector.
  7. Disconnect the fuel feed pipe quick connect fitting. Refer to Metal Collar Quick Connect Fitting Service .
  8. Disconnect the fuel return pipe from the fuel pressure regulator.

    9. Object Number: 193410 Size: SH
  9. Remove the fuel rail attaching bolts.
  10. Remove the fuel rail assembly from the cylinder head.
  11. Remove and discard the injector lower O-ring seals.

Installation Procedure

    Object Number: 193410 Size: SH
  1. Lubricate the new O-rings on the fuel injectors with clean engine oil.
  2. Install the fuel rail.

    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.

  3. Install the fuel rail attaching bolts.

    4. Tighten
    Tighten the fuel rail attaching bolts to 25 N·m (18 lb ft).

  4. Connect the fuel feed pipe quick connect fitting. Refer to Metal Collar Quick Connect Fitting Service .
  5. Connect the fuel return pipe to the fuel pressure regulator.

    6. Tighten
    Tighten the fuel return pipe fitting to 33 N·m (24 lb ft).


    Object Number: 372749 Size: SH
  6. Connect the injector connectors.
  7. Push the slide locks (2) into position.
  8. Connect the vacuum hose to the fuel pressure regulator.

    9. Object Number: 143272 Size: SH
  9. Install the air cleaner resonator bracket.

    10. Tighten

    1. Tighten the bracket nut (4) to 10 N·m (89 lb in).
    2. Tighten the bracket nut (3) to 25 N·m (18 lb ft).
    3. Tighten the bracket bolt (2) to 25 N·m (18 lb ft).
  10. Connect the negative battery cable.
  11. Inspect for fuel leaks:
    12. 11.1. Turn ON the ignition for 2 seconds.
    11.2. Turn OFF the ignition for 10 seconds.
    11.3. Turn ON the ignition.
    11.4. Inspect for fuel leaks.