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Home › Saturn › 2008 › Sky Red Line, Standard › Repair and Diagnosis › Engine Performance › System › Engine Controls And Fuel - 2.0L - Introduction (2 Of 2) › Repair Instructions › Direct Fuel Injector Replacement › Removal Procedure

Removal Procedure

    Fig 1: View Of Engine Wiring Harness Connector & Fuel Injector Wiring Harness Connector
    GM1826857Courtesy of GENERAL MOTORS CORP.
  1. Disconnect the engine wiring harness electrical connector (1) from the fuel injector wiring harness electrical connector.
  2. Remove the intake manifold. Refer to Intake Manifold Replacement .
    3. Fig 2: View Of Fuel Injector Insulator
    GM1769947Courtesy of GENERAL MOTORS CORP.
  3. Remove the fuel injector insulator.
    4. Fig 3: View Of Engine Wiring Harness Connector & High Pressure Fuel Pump
    GM1826282Courtesy of GENERAL MOTORS CORP.
  4. Relieve the high side fuel system pressure. Refer to Fuel Pressure Relief (Low Pressure Side with CH 48207)  or Fuel Pressure Relief (Low Pressure Side with CH 48027-100)  or Fuel Pressure Relief (Low Pressure Side w/o CH 48207)  or Fuel Pressure Relief (Low Pressure Side w/o CH 48027-100)  or Fuel Pressure Relief (High Pressure Side) .
  5. Disconnect the engine wiring harness electrical connector (1) from the high pressure fuel pump.
  6. Remove the engine wiring harness clip (3) from the high pressure fuel pump cover.
    7. Fig 4: View Of High Pressure Fuel Pump Cover & Bolts
    GM1826280Courtesy of GENERAL MOTORS CORP.
  7. Remove the high pressure fuel pump cover bolts.
  8. Remove the high pressure fuel pump cover.
    9. Fig 5: View Of High Pressure Fuel Pump Insulator
    GM1829002Courtesy of GENERAL MOTORS CORP.
  9. Remove the high pressure fuel pump insulator.
    10. Fig 6: High Pressure Fuel Pipe
    GM1828941Courtesy of GENERAL MOTORS CORP.
  10. Loosen the high pressure fuel pipe fitting at the fuel pump.
  11. Loosen the high pressure fuel pipe fitting at the fuel rail.
  12. Remove and discard the high pressure fuel pipe.
    13. Fig 7: View Of Fuel Rail & Bolts
    GM1829953Courtesy of GENERAL MOTORS CORP.
  13. Disconnect the fuel injector wiring harness electrical connectors from the fuel injectors.
  14. Remove the fuel rail bolts (1).
    15. IMPORTANT: Carefully remove the fuel rail. The fuel injectors may come out of the cylinder head with the fuel rail.
  15. Carefully remove the fuel rail (2).
    16. Fig 8: Identifying Direct Fuel Injector Hold Down Clamps
    GM1829978Courtesy of GENERAL MOTORS CORP.
  16. Remove and discard the direct fuel injector hold down clamps.
    17. Fig 9: View Of Fuel Injectors & Cylinder Head
    GM1830014Courtesy of GENERAL MOTORS CORP.
  17. Remove the direct fuel injectors.
    18. Fig 10: Using J 2619-01 & J-37281-A
    GM1769952Courtesy of GENERAL MOTORS CORP.
  18. If necessary, use the J 2619-01  and the J-37281-A  in order to remove the direct fuel injector(s). See Special Tools .
    19. Fig 11: View Of Fuel Injector Components
    GM1829979Courtesy of GENERAL MOTORS CORP.
  19. Remove and discard the upper O-ring seal (1) and plastic spacer (2) from the injector(s).
  20. Carefully remove and discard the lower nylon seal (4) from the injector(s).
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