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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 › Fuel Injection Fuel Rail Assembly 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. Fig 4: View Of High Pressure Fuel Pump Cover & Bolts
    GM1826280Courtesy of GENERAL MOTORS CORP.
  6. Remove the high pressure fuel pump cover bolts.
  7. Remove the high pressure fuel pump cover.
  8. Remove the engine wiring harness clip from 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. If the fuel injectors have been removed with the fuel rail, reinstall the injectors. Refer to Direct Fuel Injector Replacement .
    17. Fig 8: View Of Fuel Injector Components
    GM1829979Courtesy of GENERAL MOTORS CORP.
  17. Remove and discard the fuel injector upper O-ring seal (1).
  18. Inspect the plastic spacer (2) for damage, remove if damaged.
    19. Fig 9: View Of Fuel Rail Fuel Pressure Sensor
    GM1829977Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Applying force to the plastic housing of the sensor will destroy the sensor. To tighten or loosen, only apply force to the attached hexagon.
  19. If replacing the fuel rail, remove the fuel injection fuel rail fuel pressure sensor.
  20. Remove the fuel injector wiring harness.
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