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Home >> Saturn >> 2007 >> Sky Red Line, Standard >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls & Fuel - 2.0L - Introduction (2 Of 2) >> Repair Instructions >> Direct Fuel Injector Replacement >> Installation Procedure
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Installation Procedure

    Fig 1: Fuel Injector
    GM1829979Courtesy of GENERAL MOTORS CORP.
  1. Install a NEW plastic spacer (2) onto the fuel injector(s).
  2. Lubricate a NEW O-ring seal (1) with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
  3. Install the NEW O-ring seal (1) onto the fuel injector (s).
    4. Fig 2: Injector Tip & EN 48266-1
    GM1829992Courtesy of GENERAL MOTORS CORP.
  4. From the EN-48266  , position the EN 48266-1 to the injector tip. See Special Tools .
    5. Fig 3: Using EN 48266-1
    GM1829994Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: DO NOT lubricate the NEW seal.
  5. Install a NEW seal onto the EN 48266-1.
    6. Fig 4: EN 48266-1 Installed
    GM1829993Courtesy of GENERAL MOTORS CORP.
  6. Pull the NEW seal by hand over the EN 48266-1 and into the groove in the injector.
  7. Remove the EN 48266-1 from the injector tip.
    8. Fig 5: Injector Tip & EN 48266-2
    GM1829997Courtesy of GENERAL MOTORS CORP.
  8. From the EN-48266  , install the EN 48266-2 to the injector tip. See Special Tools .
    9. Fig 6: EN 48266-2 Installed
    GM1829998Courtesy of GENERAL MOTORS CORP.
  9. Using the EN 48266-2, resize the seal. Install the EN 48266-2, until it bottoms out against the injector body, and rotate the EN 48266-2 while applying only moderate force 180 degrees in one direction and then 180 degrees back in the other direction.
  10. Remove the EN 48266-2.
    11. Fig 7: Direct Fuel Injectors
    GM1830014Courtesy of GENERAL MOTORS CORP.
  11. Install the direct fuel injectors to the cylinder head.
    12. Fig 8: Direct Fuel Injector Hold Down Clamps
    GM1829978Courtesy of GENERAL MOTORS CORP.
  12. Install the NEW direct fuel injector hold down clamps.
    13. Fig 9: Fuel Rail Bolts
    GM1829953Courtesy of GENERAL MOTORS CORP.
  13. Place the fuel rail (2) into position.
  14. Install the 2 outer fuel rail bolts (1) first, hand tight and install the remaining 2 bolts, hand tight.
  15. Connect the fuel injector wiring harness electrical connectors (2) to the fuel injectors.
    16. Fig 10: Fuel Rail Bolt Tightening Sequence
    GM1769965Courtesy of GENERAL MOTORS CORP.
  16. Tighten the fuel rail bolts in the sequence shown.

    Tighten: 

    • Tighten the bolts a first pass to 22 N.m (16 lb ft).
    • Tighten the bolts a final pass to 22 N.m (16 lb ft).

    17. Fig 11: High Pressure Fuel Pipe
    GM1828941Courtesy of GENERAL MOTORS CORP.
  17. Ensure that the high pressure fuel pump, and fuel rail fittings are clean prior to assembly.
  18. Lubricate the high pressure fuel pump, and the fuel rail fittings with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
  19. Install the NEW high pressure fuel pipe.
  20. Tighten the NEW high pressure fuel pipe fitting to the fuel rail hand tight.
  21. Tighten the NEW high pressure fuel pipe fitting to the fuel pump hand tight.

    Tighten:  Tighten the fittings to 32 N.m (24 lb ft).

    22. Fig 12: High Pressure Fuel Pump Insulator
    GM1829002Courtesy of GENERAL MOTORS CORP.
  22. Install the high pressure fuel pump insulator.
    23. Fig 13: High Pressure Fuel Pump Cover & Bolts
    GM1826280Courtesy of GENERAL MOTORS CORP.
  23. Install the high pressure fuel pump cover.
  24. Install the high pressure fuel pump cover bolts.

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

    25. Fig 14: High Pressure Fuel Pump Connector & Clip
    GM1826282Courtesy of GENERAL MOTORS CORP.
  25. Connect the engine wiring harness electrical connector (1) to the high pressure fuel pump.
  26. Install the engine wiring harness clip (3) to the high pressure fuel pump cover.
    27. Fig 15: Fuel Injector Insulator
    GM1769947Courtesy of GENERAL MOTORS CORP.
  27. Install the fuel injector insulator.
  28. Install the intake manifold. Refer to Intake Manifold Replacement .
    29. Fig 16: Fuel Injector Wiring Harness Electrical Connector
    GM1826857Courtesy of GENERAL MOTORS CORP.
  29. Connect the engine wiring harness electrical connector (1) to the fuel injector wiring harness electrical connector.
  30. Inspect for 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, with the engine OFF.
    4. Inspect for fuel leaks.
  31. Install the low side fuel pressure service port cap.
  32. Tighten the fuel fill cap.
  33. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .
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