Installation Procedure

WARNING: This page is about a different car, the 2005 Saturn Ion 3, 2005 Saturn Ion 2, and 2005 Saturn Ion 1. However, it is still accessible from the selected car via links, so may be relevant.

Install the fuel injectors. Refer to Fuel Injector Replacement .

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.

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

NOTE: Refer to FASTENER NOTICE in Cautions and Notices.

Install the fuel rail attaching studs.
Tighten: Tighten the fuel rail studs to 10 N.m (89 lb in).
Connect the fuel injector harness connectors. Pull back to insure the connectors are locked in place.
Install the fuel supply pipe.
Tighten: Using a backup wrench on the fuel rail tighten the fuel supply pipe to 10 N.m (89 lb in).
Install the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement .
Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
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.

Fig 1: View Of Fuel Rail

Courtesy of GENERAL MOTORS CORP.