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Home >> Saturn >> 2009 >> Aura Green Line >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls And Fuel - 2.4L - Introduction >> Repair Instructions >> Fuel Injection Fuel Rail Assembly Replacement >> Installation Procedure

Installation Procedure

NOTE: Install only NEW lower O-rings if the fuel rail and injectors were removed and re-installed. If the fuel rail was replaced, then install NEW upper and lower O-rings.
    Fig 1: View Of Fuel Rail & Injectors
    GM1683401Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel injectors, if necessary. Refer to Fuel Injector Replacement .
  2. Install the fuel injector wiring harness clips to the fuel rail.
  3. Connect the fuel injector wiring harness electrical connectors to the fuel injectors.
    4. Fig 2: View Of Fuel Injector Tip Insulators
    GM1336272Courtesy of GENERAL MOTORS CORP.
  4. Lubricate the NEW fuel injector tip insulators with clean engine oil.
  5. Install the NEW fuel injector tip insulators to the cylinder head.
    6. Fig 3: View Of Fuel Rail
    GM1578472Courtesy of GENERAL MOTORS CORP.
  6. Lubricate the fuel injector O-rings with clean engine oil.
  7. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
  8. Carefully push down on the fuel rail in order to insert the injectors into the cylinder head ports.
    CAUTION: Refer to Fastener Caution .
  9. Install the fuel rail bolts and tighten to 10 N.m (89 lb in).
    10. Fig 4: Identifying Wiring Harness Clips & Fuel Rail Tabs
    GM1889953Courtesy of GENERAL MOTORS CORP.
  10. Install the engine wiring harness clips (1) to the fuel rail tabs (2).
    11. Fig 5: Identifying Fuel Injector Wiring Harness Electrical Connector
    GM1889725Courtesy of GENERAL MOTORS CORP.
  11. Connect the fuel injector wiring harness electrical (1) to the MAP sensor.
    12. Fig 6: Identifying Fuel Injector Wiring Harness Electrical Connectors
    GM1889723Courtesy of GENERAL MOTORS CORP.
  12. Connect the engine wiring harness electrical connector (3) to the fuel injector wiring harness electrical connector (4).
    13. Fig 7: Identifying Fuel Feed Line Retainer & Quick Connect Fittings
    GM1889920Courtesy of GENERAL MOTORS CORP.
  13. Connect the fuel feed line quick connect fitting (3) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  14. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (LAT) or Battery Negative Cable Disconnection and Connection (LZ4, LY7, and LE5) .
  16. Inspect for fuel leaks using the following procedure:
    1. Turn ON the ignition, with the engine OFF for 2 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition.
    4. Inspect for fuel leaks.
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