GM Cavalier/Sunbird/Skyhawk/Firenza 1982-1994

Fuel Injector

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5 and 6


WARNING
When removing the injectors, be careful not to damage the electrical connector pins (on top of the injector), the injector fuel filter and the nozzle. The fuel injector is serviced as a complete assembly ONLY. The injector is an electrical component and should not be immersed in any kind of cleaner.

  1. Properly relieve the fuel system pressure, as outlined earlier in this section.
  2.  
  3. Remove the air cleaner.
  4.  
  5. Detach the fuel injector electrical connector.
  6.  



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Fig. Fig. 1: Detach the fuel injector electrical connector



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Fig. Fig. 2: Unfasten the injector retaining screw

  1. Remove the injector retainer screw and retainer.
  2.  
  3. Using a smooth object such as a fulcrum, place the blade of a suitable prytool under the ridge opposite the connector end and carefully pry the injector out.
  4.  



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Fig. Fig. 3: Use a fulcrum to aid in prying the fuel injector out

  1. Remove and discard the upper and lower O-rings from the injector and in the fuel injector cavity.
  2.  



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Fig. Fig. 4: Remove and discard the injector O-rings and replace with new ones during installation



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Fig. Fig. 5: Always replace the O-rings with new ones

  1. Inspect the filter for evidence of dirt and/or contamination.
  2.  

To install:

Be sure to replace the injector with an identical part. Injectors from other models can fit in the Model 700, but are calibrated for different flow rates. There is a part number located on the top of the injector



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Fig. Fig. 6: To ensure that you are using the correct part, check the fuel injector part number

  1. Lubricate the new upper and lower O-rings with clean engine oil and place them on the injector. Make sure the upper O-ring is in the groove and the lower one is flush up against the filter.
  2.  
  3. Install the fuel injector assembly as follows:
    1. Position the injector in the fuel meter body with the electrical connector facing the cut-out for the wire grommet.
    2.  
    3. Push the injector down to seat it in the cavity.
    4.  

  4.  

Make sure the electrical connector end on the injector is facing in the general direction to the cut-out in the fuel meter body for the wire grommet.

  1. Install the injector retainer, using appropriate thread locking compound on the retainer attaching screw. Tighten to 27 inch lbs. (3 Nm).
  2.  
  3. Tighten the fuel filler cap, if loosened during fuel pressure relief procedure.
  4.  
  5. Connect the negative battery cable, then with the engine OFF , check to see that the accelerator pedal is free by depressing, then releasing it. Turn the ignition switch to the ON position for 2 seconds, then turn to the OFF position for 10 seconds. Again turn the switch to the ON position and check for fuel leaks.
  6.  
  7. Install the air cleaner assembly and gasket.
  8.  

 
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