Fuel rail with injectors (B235R, B205L/R): Dismantling

WARNING: This page is about a different car, the 2001 Saab 9-3. However, it is still accessible from the selected car via links, so may be relevant.

IMPORTANT: The utmost cleanliness must be observed when handling the fuel rails and injectors. Wash around the injectors, fuel rail and intake manifold and dry with compressed air.

Remove the upper engine cover.

Fig 1: Illustration For Step 1-2
Remove fuse 32 for the fuel pump while the engine is running. Switch off the ignition once the engine has stopped. Refit fuse 32 for the fuel pump.
Detach the crankcase ventilation hoses.

Fig 2: Illustration For Steps 3-4-5-6
Disconnect the fuel line connections from the fuel rail using special tool 83 95 261 Fuel line tool.
Use also a rag or other cloth to collect excess fuel.
Remove the dipstick and filler pipe and plug the pipe.
Remove the cover over the throttle valve. Detach the accelerator wire from the throttle spindle. Remove the accelerator wire with holder and bend it to one side.
Detach the cable channel, 3 screws, and put it to one side.

Fig 3: Illustration For Steps 7-8-9
Cut the cable tie securing the check valve to the camshaft cover.
Unplug the injector connectors.
IMPORTANT: 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.
Blow clean around the injectors with compressed air.
Undo the two rail retaining screws.

Fig 4: Illustration For Steps 11-12-14
Detach the pressure regulator vacuum hose.
Carefully pry off the rail using 2 crowbars or similar tool.
Carefully lift out the rail.
Plug the nozzle holes.