GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2002 🢒 L100/L200/LW200 🢒 Engine 🢒 Engine Controls - 2.2L (L61) 🢒 Fuel Injection Fuel Rail Assembly Replacement

Removal Procedure

    Caution: Refer to Gasoline/Gasoline Vapors Caution in the Preface section.


    Object Number: 896381 Size: SH

    Important: When servicing the fuel rail assembly, be careful to prevent dirt and other contaminants from entering the fuel passages. Fittings should be capped and holes plugged during servicing. Before removal, the fuel rail may be cleaned with a spray type engine cleaner, AC Delco X-30A, or equivalent, following the package instructions. Do not soak the rails in liquid cleaning solvent.

  1. Disconnect the negative battery terminal.
  2. Remove the air intake tube and fresh air tube.

    3. Caution: Refer to Relieving Fuel Pressure Caution in the Preface section.


    Object Number: 893318 Size: SH
  3. Relieve the fuel system pressure. Refer to Fuel System Diagnosis .

    4. Object Number: 895185 Size: SH
  4. Disconnect the fuel pressure regulator hose from the throttle body and the fuel rail.
  5. Disconnect the fuel supply line by compressing the 2 plastic retainer tabs and pulling on the fuel supply line. Remove and discard the plastic retainer.
  6. Remove the throttle body.
  7. Remove the throttle control cable bracket bolts, disconnect the cable from the throttle lever, and lay it over the intake manifold.
  8. Disconnect the injector electrical connectors.

    9. Object Number: 895190 Size: SH
  9. Remove the fuel rail assembly attachment bolts.

    10. Notice: Use care in removing the fuel rail assembly to prevent damage to the electrical connector terminals and spray tips. The fuel injector is serviced as a complete assembly only. Support fuel after fuel rail is removed in order to avoid damaging fuel rail components. Since it is electrical, it should not be immersed in any cleaner.

  10. Remove the fuel rail assembly:
    11. • Carefully pull the rail back and upward to remove the injectors from the cylinder head ports.
    • Move the rail towards the power steering pump.
    • Rotate the rail so the injectors point downward.

       Important: Whenever the fuel rail is removed for service, the injectors must be removed and upper and lower injector O-rings must be replaced.

    • Lift the #1 injector and remove the rail.

    Object Number: 896413 Size: SH
  11. Remove the clips retaining the fuel injectors and pull the injectors out of the rail.
  12. Disassemble the injector O-ring seals, using a special seal removal tool or brass seal pick, from each injector and discard.

    13. Notice: When cleaning or servicing the fuel rail, care must be taken to assure that the plastic fuel rail surfaces that mate to the injector O-rings are not scratched.

  13. Lubricate the new O-ring seals with clean engine oil and install the injectors into the fuel rail.

Installation Procedure

    Object Number: 895190 Size: SH

    Important: Lubricate the O-rings at the injector tips prior to installing the injectors into the intake manifold.

  1. To install the fuel rail assembly to intake manifold do the following:
    2. 1.1. With the injectors pointing downward, lower the fuel line end of the fuel rail into the cylinder head ports.
    1.2. Rotate the injectors into a horizontal position.
    1.3. Align the injectors with their respective port holes.
    1.4. Carefully push the fuel injectors into the holes making sure they have seated in the cylinder head.

    Notice: Refer to Fastener Notice in the Preface section.

  2. Install the fuel rail attaching bolts.

    3. Tighten
    Tighten the fuel rail attaching bolts to 10 N·m(89 lb in).

  3. Connect the fuel injector electrical connectors. Push in until a click is heard and pull back to ensure engagement.
  4. Connect the PCV valve hose and connect the vacuum line to fuel pressure regulator. Make sure they are fully seated.

    5. Notice: Lubricate with clean engine oil the male end of the fuel rail that connects with the fuel supply line. Firmly press on the female coupler until a click is heard, then pull back to confirm engagement. Pinched, kinked, or damaged fuel lines must be replaced.

  5. Lubricate with clean engine oil the male fuel feed line and male fuel return line connections. Attach the fuel feed line and pull back to confirm engagement. Attach the fuel return line and pull back to confirm engagement.
  6. Connect the negative battery terminal.

    7. Tighten
    Tighten the battery terminal bolts to 17 N·m (17 lb ft).

  7. Prime the fuel system.
    8. 7.1. Cycle the ignition ON for 5 seconds and then OFF for 10 seconds.
    7.2. Repeat step 7.1 twice.
    7.3. Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds.
    7.4. If the engine does not start, repeat steps 7.1-7.3.
  8. With engine OFF and the ignition ON, pressurize the fuel system and inspect for leaks.
  9. Install the air tube and air filter cover.