2004 Saturn Ion 1 AutomaticFACTORY OEM SERVICE PROCEDURE

Installation Procedure

  1. Install the fuel injectors. Refer to Fuel Injector Replacement .
    2. IMPORTANT: Install new lower O-rings when reusing fuel injectors. Lubricate the injector tip O-rings prior to installing the injectors into the intake manifold.
  2. Install the fuel rail using the following procedure:
    1. With the fuel injectors positioned downward, lower the fuel injectors into the cylinder head ports.
    2. Align the injectors by rotating the fuel rail forward.
    3. Carefully push the fuel injectors into the cylinder head ports.
    3. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Install the fuel rail attaching studs.

    Tighten:  Tighten the fuel rail studs to 10 N.m (89 lb in).

    4. Fig 1: View Of Fuel Rail
    GM854296Courtesy of GENERAL MOTORS CORP.
  4. Connect the fuel injector harness connectors. Pull back to insure the connectors are locked in place.
  5. Install the fuel supply pipe.

    Tighten:  Using a backup wrench on the fuel rail tighten the fuel supply pipe to 10 N.m (89 lb in).

  6. Install the air cleaner outlet resonator. Refer to Air Cleaner Outlet Resonator Replacement .
  7. Connect the negative battery cable. Refer toBattery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  8. Inspect for fuel 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.
    4. Inspect for fuel leaks.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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