ION, L-Series, S-Series 1999-2005

Fuel Injectors

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Removal & Installation



  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
     
    Air intake tube
     
    Fuel pressure regulator hose
     
    Fuel feed line
     
    Throttle body
     
    Throttle control cable bracket
     
    Fuel injector electrical connectors
     
    Fuel rail
     
    Fuel injector retaining clip off the injector
     
    Fuel injector
     
    Fuel injector O-rings

    Click image to see an enlarged view

    Fig. Remove the retainer clip from the fuel injector-2.2L and 3.0L engines

     

  6.  

To install:

  1. Lubricate the new fuel injector O-ring with clean engine oil.
  2.  
  3. Install or connect the following:

    New O-ring seals on the fuel injector
     
    Retaining clip to the fuel injector
     
    Fuel injector to the fuel rail
     
    Fuel rail and torque the bolts to 89 inch lbs. (10 Nm) on 2.2L engines and 71 inch lbs. (8 Nm) on 3.0L engines
     
    Fuel injector electrical connectors
     
    Throttle control cable bracket
     
    Throttle body and torque the bolts to 89 inch lbs. (10 Nm)
     
    Fuel feed line
     
    Fuel pressure regulator hose
     
    Air intake tube
     
    Negative battery cable
     

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

Testing



Electrical Test
  1. Unplug the injector connector and use an ohmmeter to check the resistance of the injector coil. It should be 1-2 ohms.
  2.  
  3. Connect a Noid light (or an equivalent low voltage injector harness tester) to the injector connector terminal. Position the harness so the light can be seen from the driver's seat. Then, operate the starter and observe the Noid light.
  4.  
  5. If the Noid does not illuminate at all, check for power to the injector(s). The injectors receive power through the pink/black wire from the 7.5 Amp -INJ'' fuse in the underhood junction box, any time the ignition switch is ON . The PCM operates the injectors by completing the ground circuit through the light blue wire.
  6.  
  7. If the test light stays on steadily, check for a short to ground of the wire between the injector connector and the PCM.
  8.  
  9. A pulsing Noid light does not necessarily indicate enough voltage to properly operate the fuel injector. If it is still questionable whether or not an injector is pulsing, connect a known good injector to the circuit and tightly grip the injector while an assistant cranks the engine. If injector pulses are felt, the circuit is good.
  10.  

Pressure Test
  1. Connect the test gauge and run the fuel pump and system pressure tests as described in the Fuel Pump tests earlier in this section.
  2.  
  3. Disconnect the fuel return hose from the metal line and cap the line carefully, as full fuel pressure may go as high as 94 psi (650 kPa).
  4.  
  5. Disconnect the pressure regulator vacuum line.
  6.  
  7. Cycle the ignition ON and OFF , without starting the engine, to build system pressure to a minimum of 58 psi (400 kPa) on the gauge.
  8.  
  9. Look into the throttle body. If there is a leak, there will be drops of fuel on the throttle plate. The leak could from be the injector O-ring, the injector tip or the pressure regulator diaphragm.
  10.  
  11. If necessary, remove and examine the injector; a leak will be obvious.
  12.  

 
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