Saab 2000-06

Fuel Rail (Supply Manifold) & Injectors

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Removal & Installation



9-3
2.0L & 2.3L Engines

CAUTION
The fuel injection system remains under pressure, even after the engine has been tuned OFF . The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Detach the crankcase vent hoses.
  8.  
  9. Remove or disconnect the following:
    WARNING
    Secure each injector clip with a narrow cable tie. Make sure they are positioned correctly and tighten them. Otherwise, the injectors may come loose from the fuel rail while being removed.


    CAUTION
    To prevent entry of foreign matter, regularly blow around the injectors with compressed air.



    Fuel line connections from fuel rail
     
    Dipstick and filler pipe (plug pipe opening)
     
    Cover over throttle valve
     
    Accelerator wire from throttle spindle
     
    Accelerator wire with holder (bend it to one side)
     
    Cable channel (put it to one side)
     
    Cable tie securing check valve to camshaft cover
     
    Injector connectors
     

  10.  
  11. Undo both rail retaining screws.
  12.  
  13. Detach the pressure regulator vacuum hose.
  14.  
  15. Carefully pry off the rail using 2 crowbars or similar tool and lift out the rail.
  16.  
  17. Plug the nozzle holes.
  18.  

To install:

  1. Remove the plugs in the nozzle holes and lubricate the injector O-rings.
  2.  
  3. Carefully lift the rail into position and attach with 2 screws.
  4.  
  5. Install or connect the following:

    Pressure regulator vacuum hose
     
    Remove the cable ties round the injectors.
     
    Plug in injector connectors
     
    Cable channel and fit the 3 screws
     
    Check valve to camshaft cover with cable tie
     
    Throttle cable and bracket (adjust the throttle cable)
     
    Throttle valve cover
     
    Dipstick and filler pipe
     
    Crankcase ventilation hoses
     
    Fuel connections to fuel rail
     
    Upper engine cover
     
    Negative battery cable
     

  6.  

2.8L Engine

CAUTION
The fuel injection system remains under pressure, even after the engine has been tuned OFF . The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the upper intake manifold.
  8.  
  9. Remove the intake manifold gaskets.
  10.  
  11. Unplug the injector connectors using a small screwdriver.
  12.  
  13. Detach the injectors' wiring harness.
  14.  
  15. Unplug the fuel pressure sensor connector.
  16.  
  17. Release any fuel pressure by pressing in the needle valve on the fuel rail. Catch any fuel spill with a cloth.
  18.  
  19. Detach the fuel line from the fuel rail using 83 95 261 Fuel line tool. Catch any fuel spill.
  20.  
  21. Remove the bolts. Remove the fuel rail with injectors from the engine.
  22.  
  23. Remove the clips from the valves.
  24.  
  25. Remove the valves from the fuel rail.
  26.  

To install:

  1. Install the injectors to the fuel rail using new seals coated with acid-free vaseline. Fit the clips on the injectors and press them into the fuel rail.
  2.  
  3. Install the fuel rail with injectors to the engine. Fit the bolts and tighten to 7 ft. lbs. (10 Nm).
  4.  
  5. Connect the fuel line to the fuel rail.
  6.  
  7. Plug in the fuel pressure sensor connector.
  8.  
  9. Connect the injectors' wiring harness.
  10.  
  11. Plug in the injector connectors.
  12.  
  13. Install the intake manifold gaskets.
  14.  
  15. Install the upper intake manifold.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Start the vehicle, check for leaks and repair if necessary.
  20.  

9-5
2.3L Engine

CAUTION
The fuel injection system remains under pressure, even after the engine has been tuned OFF . The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Upper engine cover
     
    Crankcase ventilation hoses
     
    Dipstick with the oil filler pipe
     
    Cover and detach the throttle cable from the spindle
     
    Turbocharger delivery pipe
     
    Fuel injector connectors
     
    Ignition discharge module
     
    Manifold Absolute Pressure (MAP) sensor
     
    Boost pressure control valve
     
    Turbocharger pressure sensor and slacken the upper bolt on the wiring holder
     
    Fuel rail retaining bolts and cable ties
     
    Fuel lines
     
    Pressure regulator vacuum hose
     
    Fuel rail with the injectors
     
    Fuel injector locking clips
     
    Fuel injectors

    Click image to see an enlarged view

    Fig. Remove the fuel rail and injectors as an assembly

     

  6.  

To install:

  1. Lubricate the O-rings on the fuel injectors
  2.  
  3. Install or connect the following:

    Fuel injectors to the fuel rail and make certain that the injectors are fitted to the proper cables
     
    Fuel rail and torque the bolts to 6 ft. lbs. (8 Nm)
     
    Vacuum hose to the pressure regulator
     
    Fuel injector hoses
     
    Screws for the wiring holder
     
    Throttle cable and cover and adjust if necessary
     
    Dipstick and filler pipe
     
    Crankcase ventilation hoses
     
    Upper engine cover
     
    Negative battery cable
     

  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

3.0L Engine

CAUTION
The fuel injection system remains under pressure, even after the engine has been tuned OFF . The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover
     
    Turbocharger delivery hose from the throttle body
     
    Throttle body from the intake manifold
     
    Upper intake manifold
     
    Fuel rail wiring
     
    Vacuum hose from the fuel pressure regulator
     
    Fuel rail and injectors as an assembly
     

  6.  

To install:

  1. Install or connect the following:

    New O-rings on the injectors
     
    Fuel rail and injectors as an assembly and torque the bolts to 6 ft. lbs. (8 Nm)
     
    Fuel pressure regulator vacuum hose
     
    Fuel lines and wiring
     
    Upper intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Throttle body
     
    Throttle cable and adjust if needed
     
    Turbocharger delivery hose
     
    Engine cover
     
    Negative battery cable
     

  2.  
  3. Start the vehicle, check for leaks and repair if necessary.
  4.  

 
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