2005 Saturn Relay AWDFACTORY OEM SERVICE PROCEDURE

Installation Procedure

    NOTE:
    • Use care when servicing the fuel system components, especially the fuel injector electrical connectors, the fuel injector tips, and the injector O-rings. Plug the inlet and the outlet ports of the fuel rail in order to prevent contamination.
    • Do not use compressed air to clean the fuel rail assembly as this may damage the fuel rail components.
    • Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to the fuel rail assembly.
  1. If the fuel injectors were removed from the fuel rail, refer to Fuel Injector Replacement .
    2. Fig 1: Identifying MAP Sensor Retaining Bolt & Bracket
    GM1544765Courtesy of GENERAL MOTORS CORP.
  2. Lubricate the fuel injector O-rings using GM P/N 12345616, (Canadian P/N 993182).
  3. Install the fuel injector nozzles into the lower intake manifold injector bores.
  4. Press on the fuel rail (2) using the palms of both hands until the fuel injectors are fully seated.
    5. NOTE: Refer to Fastener Notice in Cautions and Notices.
  5. Install the fuel rail attaching bolts (1).

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

  6. Install the injector electrical harness to the fuel rail.
  7. Apply lubricant to the fuel injector electrical connectors. GM P/N 12377900, (Canadian P/N 10953529).
  8. Connect the fuel injector electrical connectors.
  9. Connect the coolant temperature sensor and camshaft position sensor electrical connectors.
  10. Connect the main fuel injector electrical harness connector.
    11. Fig 2: View Of Fuel Hoses/Pipes
    GM1544724Courtesy of GENERAL MOTORS CORP.
  11. Connect the engine fuel feed pipe (3) to the fuel rail (1). Refer to Quick Connect Fitting(s) Service (Metal Collar) .
  12. Connect the EVAP pipe (5) to the EVAP canister purge solenoid valve (4). Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  13. Install the upper intake manifold. Refer to Intake Manifold Installation - Upper in Engine Mechanical.
  14. Connect the negative battery cable.
  15. Inspect for fuel leaks.
    1. Turn ON the ignition 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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