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Home >> Saturn >> 2010 >> Sky Red Line, Automatic >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Engine Controls And Fuel - 2.0L - Repair Instructions >> Repair Instructions >> Fuel Injection Fuel Rail Assembly Replacement >> Installation Procedure
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Installation Procedure

    Fig 1: View Of Fuel Rail Fuel Pressure Sensor
    GM1829977Courtesy of GENERAL MOTORS CORP.
  1. If the fuel rail was replaced, lubricate the threads and sealing cone of the NEW fuel rail with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
  2. Lubricate the threads and sealing cone of the sensor with silicon free engine oil GM P/N 12345610 (Canadian P/N 993193) or equivalent.
    3. CAUTION: Refer to Fastener Caution .
    NOTE: Applying force to the plastic housing of the sensor will destroy the sensor. To tighten or loosen, only apply force to the attached hexagon.
  3. Install the fuel injection fuel rail fuel pressure sensor and tighten to 33 N.m (25 lb ft).
  4. Install the fuel injector wiring harness.
    5. Fig 2: Identifying Fuel Rail & Bolts
    GM1829953Courtesy of GENERAL MOTORS CORP.
  5. Place the fuel rail (2) into position.
  6. 9. Install the fuel rail with injectors into the cylinder head evenly.
  7. Install the 2 outer fuel rail bolts (1) first hand tight, and then install the remaining 2 bolts, hand tight.
  8. Connect the fuel injector wiring harness electrical connectors to the fuel injectors.
    9. Fig 3: Identifying Fuel Rail Bolt Tightening Sequence
    GM1769965Courtesy of GENERAL MOTORS CORP.
  9. Tighten the fuel rail bolts in the sequence shown.
    • 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).
    10. Fig 4: View Of High Pressure Fuel Pipe
    GM1828941Courtesy of GENERAL MOTORS CORP.
  10. Ensure that the high pressure fuel pump, and fuel rail fittings are clean prior to assembly.
  11. 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.
  12. Install a NEW high pressure fuel pipe.
  13. Tighten the NEW high pressure fuel pipe fitting to the fuel rail hand tight.
  14. Tighten the NEW high pressure fuel pipe fitting to the fuel pump hand tight to 32 N.m (24 lb ft).
    15. Fig 5: View Of High Pressure Fuel Pump Insulator
    GM1829002Courtesy of GENERAL MOTORS CORP.
  15. Install the high pressure fuel pump insulator.
    16. Fig 6: View Of High Pressure Fuel Pump Cover & Bolts
    GM1826280Courtesy of GENERAL MOTORS CORP.
  16. Install the engine wiring harness clip to the high pressure fuel pump cover.
  17. Install the high pressure fuel pump cover.
  18. Install the high pressure fuel pump cover bolts and tighten to 10 N.m (89 lb in).
    19. Fig 7: Identifying High Pressure Fuel Pump Connector & Clip
    GM1826282Courtesy of GENERAL MOTORS CORP.
  19. Connect the engine wiring harness electrical connector (1) to the high pressure fuel pump.
    20. Fig 8: View Of Fuel Injector Insulator
    GM1769947Courtesy of GENERAL MOTORS CORP.
  20. Install the fuel injector insulator.
  21. Install the intake manifold. Refer to Intake Manifold Replacement .
    22. Fig 9: Identifying Fuel Injector Wiring Harness Electrical Connector
    GM1826857Courtesy of GENERAL MOTORS CORP.
  22. Connect the engine wiring harness electrical connector (1) to the fuel injector wiring harness electrical connector.
  23. 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.
  24. Install the low side fuel pressure service port cap.
  25. Tighten the fuel fill cap.
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