GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2003 🢒 ION 🢒 Engine 🢒 Engine Controls - 2.2L (L61) 🢒 Fuel Injection Fuel Rail Assembly Replacement

Removal Procedure
  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. Use a back up wrench on the fuel rail and disconnect the fuel supply pipe.
  4. Disconnect the fuel injector harness connectors.

    5. Object Number: 854296 Size: SH
  5. Remove the fuel rail attaching studs.

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

  6. Remove the fuel rail using the following procedure:
    7. 6.1. Pull the fuel rail back and upward to remove the fuel injectors from the cylinder head ports.
    6.2. Rotate the fuel rail in order to position the injectors downward.
    6.3. Remove the fuel rail.
  7. Remove the fuel injectors. Refer to Fuel Injector Replacement .

Installation Procedure
  1. Install the fuel injectors. Refer to Fuel Injector Replacement .

    2. Object Number: 854296 Size: SH

    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.

  2. Install the fuel rail using the following procedure:
    3. 2.1. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
    2.2. Align the injectors by rotating the fuel rail forward.
    2.3. Carefully push the fuel injectors into the cylinder head ports.

    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 studs.

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

  4. Connect the fuel injector harness connectors. Pull back to insure the connectors are locked in place.
  5. Install the fuel supply pipe.

    6. Tighten
    Using a backup wrench on the fuel rail tighten the fuel supply pipe to 10 N·m (89 lb in).

  6. Install the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement .
  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.