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Home >> Saturn >> 2004 >> L300 4D Sedan, 2.2 F >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - 2.2L (L61) (Introduction) >> Repair Instructions >> Fuel Rail Assembly Replacement >> Removal Procedure
July 1: So it begins. Don't worry, this is not in the correct legal jurisdiction!

Removal Procedure

CAUTION: Do not allow smoking or the use of open flames in the area where work on the fuel or EVAP system is taking place. Anytime work is being done on the fuel system, disconnect the negative battery cable, except for those tests where battery voltage is required.
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, ACDelco 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. Fig 1: Removing & Installing Air Inlet Tube & Air Cleaner Assembly
    GM896381Courtesy of GENERAL MOTORS CORP.
    CAUTION: Whenever fuel line fittings are loosened or disconnected, wrap a shop cloth around the fitting to collect fuel. Place the cloth in an approved container.
  3. Relieve the fuel system pressure. Refer to Fuel System Diagnosis .
    4. Fig 2: Proper Connection Of Pressure Adapter & Gage Bar Set To Fuel Rail
    GM893318Courtesy of GENERAL MOTORS CORP.
  4. Disconnect the fuel pressure regulator hose from the throttle body and the fuel rail.
    5. Fig 3: Identifying Fuel Pressure Regulator Hose
    GM895185Courtesy of GENERAL MOTORS CORP.
    CAUTION: Whenever fuel line fittings are loosened or disconnected, wrap a shop cloth around the fitting to collect fuel. Place the cloth in an approved container.
  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. Remove the fuel rail assembly attachment bolts.
    10. NOTE: 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:
    1. Carefully pull the rail back and upward to remove the injectors from the cylinder head ports.
    2. Move the rail towards the power steering pump.
    3. Rotate the rail so the injectors point downward.
      4. IMPORTANT: Whenever the fuel rail is removed for service, the injectors must be removed and upper and lower injector O-rings must be replaced.
    4. Lift the #1 injector and remove the rail.
    11. Fig 4: Removing & Installing Fuel Rail Assembly
    GM895190Courtesy of GENERAL MOTORS CORP.
  11. Remove the clips retaining the fuel injectors and pull the injectors out of the rail.
    12. Fig 5: Removing & Installing Fuel Injector
    GM896413Courtesy of GENERAL MOTORS CORP.
  12. Disassemble the injector O-ring seals, using a special seal removal tool or brass seal pick, from each injector and discard.
    13. NOTE: 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.
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