GM Cavalier/Sunbird/Skyhawk/Firenza 1982-1994

Fuel Injectors

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REMOVAL & INSTALLATION



1.8L and 2.0L OHC Engines

See Figures 1, 2 and 3



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Fig. Fig. 1: Exploded view of the fuel injector, retaining clip and O-rings


WARNING
Use care in removing the fuel injectors to prevent damage to the electrical connector pins on the injector and the nozzle. The fuel injector is serviced as a complete assembly only and should not be immersed in any kind of cleaner.

  1. Properly relieve fuel system pressure, as outlined earlier in this section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the throttle body from the intake manifold.
  6.  
  7. As outlined later in this section, remove the fuel rail.
  8.  
  9. Unfasten and discard the injector retaining clip, then remove the injector assembly. Remove and discard the O-rings from each end of the injector.
  10.  



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Fig. Fig. 2: Removing the fuel injector retaining clip

To install:


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Fig. Fig. 3: Push the fuel injector into the socket, making sure it is fully seated

  1. Lubricate new O-rings with clean engine oil, the install on the injector.
  2.  
  3. Position a new injector retaining clip on the injector.
  4.  
  5. Install the injector assembly into the fuel rail injector socket, with the electrical connector facing inward toward the manifold. Push the socket in far enough to engage the retainer clip with the groove on the rail.
  6.  
  7. Install the fuel rail assembly and throttle body.
  8.  
  9. Connect the negative battery cable.
  10.  

2.8L and 3.1L Engines
1985-86 VEHICLES

See Figure 4

Each port injector is located and held in position by a retainer clip that must be rotated to release and/or lock the injector in place.



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Fig. Fig. 4: Fuel rail, injectors and manifold - 1985-86 2.8L vehicles

  1. Disconnect the negative battery cable.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove the plenum and the fuel rail.
  6.  
  7. Rotate the injector retaining clip(s) the the unlocked position.
  8.  
  9. Remove the port injectors. Remove and discard the injector O-rings.
  10.  

To install:
  1. Install new O-ring seals and lubricate with engine oil.
  2.  
  3. Position the injectors to the fuel rail and pressure regulator assembly.
  4.  
  5. Rotate the injector retaining clips to the locking position.
  6.  
  7. Install the fuel rail and the plenum.
  8.  
  9. Connect the negative battery cable.
  10.  

1987-94 VEHICLES

See Figures 5, 6 and 7

  1. Disconnect the negative battery cable.
  2.  



Click image to see an enlarged view

Fig. Fig. 5: Exploded view of the fuel rail, injectors, retaining clip and O-rings



Click image to see an enlarged view

Fig. Fig. 6: You must remove the plenum and fuel rail for access to the injectors

  1. Properly relieve the fuel system pressure.
  2.  
  3. Remove the intake manifold plenum.
  4.  
  5. As outlined later in this section, remove the fuel rail.
  6.  
  7. Unfasten and discard the injector retaining clip, then remove the fuel injector assembly. Remove and discard the O-rings from each end of the injector.
  8.  



Click image to see an enlarged view

Fig. Fig. 7: Push the fuel injector into the socket, making sure it is fully seated

To install:
  1. Lubricate new O-rings with clean engine oil, the install on the injector.
  2.  
  3. Position a new injector retaining clip on the injector. Place the open end of the clip facing the injector electrical connector.
  4.  
  5. Install the injector assembly into the fuel rail injector socket, with the electrical connector facing outward. Push it in far enough to engage the retainer clip with the machined slots on the rail.
  6.  
  7. Install the fuel rail assembly and throttle body.
  8.  
  9. Connect the negative battery cable.
  10.  

This test must be done before the engine is started and requires the use of a Tech 1® scan tool.

  1. If equipped with the 3.1L engine, perform the idle learn procedure to allow the ECM/PCM memory to be updated with the correct IAC valve pintle position and provide for a stable idle speed.
    1. Install a Tech 1® scan tool.
    2.  
    3. Turn the ignition to the ON position, engine not running.
    4.  
    5. Select IAC SYSTEM , then IDLE LEARN in the MISC TEST mode.
    6.  
    7. Place the transaxle in park or neutral, as applicable.
    8.  
    9. Proceed with idle learn as directed by the scan tool.
    10.  

  2.  

 
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