GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2005 🢒 ION 🢒 Vehicle Control Systems 🢒 Vehicle DTC Information 🢒 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. Disconnect the fuel line fitting. Refer to Metal Collar Quick Connect Fitting Service .
  4. Disconnect the fuel injector harness connectors.

    5. Object Number: 1578472 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: 1578472 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: Refer to Fastener Notice in the Preface section.

  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. Connect the fuel line fitting. Refer to Metal Collar Quick Connect Fitting Service .
  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 .
  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.