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Home >> Saturn >> 2005 >> L300 >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls - Introduction >> Repair Instructions >> Fuel Rail Assembly Replacement >> Removal Procedure
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Removal Procedure

    Fig 1: Proper Connection Of Pressure Adapter & Gage Bar Set To Fuel Rail
    GM894302Courtesy of GENERAL MOTORS CORP.
    CAUTION: Locate class B fire extinguisher in work area.
    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.
    IMPORTANT: Cap the fuel fittings and plug the port holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open areas.
  1. Disconnect the negative battery terminal.
  2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  3. Disconnect the fuel lines.
    4. Fig 2: Removing/Installing Fuel Rail Assembly
    GM896453Courtesy of GENERAL MOTORS CORP.
  4. Remove the intake plenum. Refer to Intake Plenum Replacement .
  5. Disconnect the fuel injector electrical harness connector.
  6. Disconnect the fuel injector connectors.
  7. Remove the fuel rail attaching bolts from the intake manifold.
  8. Disconnect the fuel pressure regulator vacuum line.
    9. CAUTION: Wear safety glasses when using compressed air in order to prevent eye injury.
  9. Use compressed air to blow debris away from the area where the injectors enter the intake manifold.
  10. Remove the fuel injector locking clips. Pry each fuel injector from the intake manifold.
  11. Remove the fuel rail assembly.
  12. Remove the fuel injector assemblies from the fuel rail.
    13. IMPORTANT: Any time the fuel system is opened for service, the O-ring seals used with related components must be replaced.
  13. Remove rust or burrs from the engine fuel pipes using the following procedures:
    1. Use emery cloth in order to remove rust or burrs from the fuel pipes. Use a radial motion on the fuel pipe end in order to prevent damage to the O-ring sealing surface.
    2. Use a clean shop towel to wipe the male tube ends clean.
    3. Inspect all connectors for dirt and burrs. Clean or replace the damaged components as necessary.
  14. Remove the O-rings from the fuel injectors.
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