Alero, Grand Am 1999-2005

Fuel Injectors

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Removal & Installation



2.2L Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Be careful when removing the fuel rail so that you do not damage the injector tips or electrical connections.



    Air cleaner outlet resonator
     
    Vacuum pipe from the fuel pressure regulator
     
    Engine fuel supply and return pipes
     
    Fuel injector harness connectors
     
    Fuel rail attaching studs.
     

  6.  
  7. Remove the fuel rail as follows:
    1. Pull the fuel rail back and upward to remove the fuel injectors from the ports.
    2.  
    3. Rotate the fuel rail to position the injectors downward.
    4.  
    5. Remove the fuel rail.
    6.  

  8.  
  9. Remove or disconnect the following:

    Fuel injector retainer clip
     
    Fuel injector from the fuel rail
     

  10.  
  11. Inspect the fuel injector in order to determine if the upper O-ring was also removed. If the upper O-ring in not removed, remove the O-ring from the fuel rail assembly.

    Fuel injector O-rings and discard
     

  12.  

To install:

  1. Install or connect the following:
    NOTE
    The fuel injector will click when the injector is installed correctly.



    O-rings on the fuel injector
     
    Fuel injector clip on the fuel injector
     



    Fuel injector to the fuel rail with the connector facing upward
     

  2.  
  3. Install the fuel rail as follows:
    1. With the fuel injectors positioned downward, lower the fuel injectors into the ports.
    2.  
    3. Align the injectors by rotating the fuel rail forward.
    4.  
    5. Carefully push the fuel injectors into the cylinder head ports.
    6.  
    7. Install and tighten the fuel rail retainers to 89 inch lbs. (10 Nm).

      Fuel injector harness connectors. Gently pull on the connectors to make sure they are fully engaged.
       
      Fuel supply and return pipes
       
      Vacuum pipe to the fuel pressure regulator
       
      Air cleaner outlet resonator
       
      Negative battery cable
       

    8.  

  4.  
  5. Inspect for fuel leaks using the following procedure:
    1. Turn ON the ignition, with the engine OFF for 2 seconds.
    2.  
    3. Turn OFF the ignition for 10 seconds.
    4.  
    5. Turn ON the ignition.
    6.  
    7. Inspect for fuel leaks.
    8.  

  6.  

3.1L & 3.4L Engines
  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Upper intake manifold
     
    Fuel feed pipe
     
    Fuel return pipe from the pressure regulator
     
    Main fuel injector wiring harness electrical connector
     
    Engine Coolant Temperature (ECT) sensor electrical connector
     
    Fuel rail assembly
     
    Fuel injector electrical connectors
     
    Fuel injector-to-fuel rail clip
     
    Fuel injector

    Click image to see an enlarged view

    Fig. Exploded view of the fuel rail assembly-3.1L & 3.4L engines



    Click image to see an enlarged view

    Fig. Exploded view of the fuel injector-3.1L & 3.4L engine shown

     

  6.  

To install:


WARNING
If the fuel injector O-rings are color coded, install the black O-ring in the upper position and the brown O-ring in the lower position.

  1. Lubricate the O-rings with engine oil prior to installation.
  2.  
  3. Install or connect the following:

    New fuel injector O-rings
     
    Fuel injector
     
    Fuel injector retaining clip
     
    Fuel injector electrical connectors
     
    Fuel rail assembly. Torque the bolts to 89 inch lbs. (10 Nm).
     
    ECT sensor electrical connector
     
    Main fuel injector wiring harness electrical connector
     
    New fuel pipe O-rings lubricated with engine oil
     
    Fuel feed pipe at the fuel rail. Torque the pipe nut to 13 ft. lbs. (17 Nm).
     
    Fuel return pipe to the pressure regulator. Torque the pipe nut to 13 ft. lbs. (17 Nm).
     
    Upper intake manifold
     

  4.  
  5. Re-pressurize the fuel system and check for leaks.
  6.  

 
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