REMOVAL & INSTALLATION
See Figures 1 and 2
The bottom feed fuel injectors on the 2.2L engine are installed to the lower intake manifold assembly. For access, the upper intake manifold must first be removed.
Take care when servicing the lower intake manifold and fuel injectors to prevent dirt or contaminants from entering the fuel system. ALL openings in the fuel lines and passages should be capped or plugged while disconnected.
- Properly relieve the fuel system pressure, then disconnect the negative battery cable.
- Remove the accelerator bracket retaining bolts/nuts, then remove or reposition the bracket.
- Remove the upper intake manifold assembly. For details, please refer to the intake manifold procedures in Engine & Engine Overhaul of this repair guide.
- Remove the fuel return line bracket nut, then remove the return line retaining bracket and position it away from the pressure regulator.
- Remove the fuel pressure regulator assembly. For details, please refer to the procedure later in this section.
DO NOT attempt to remove the injectors from their bores while lifting upward on the retaining bracket, or damage may occur. DO NOT attempt to remove the bracket without first removing the pressure regulator.
- Remove the fuel injector retainer bracket attaching screws, then remove the bracket by carefully sliding it off to clear the injector slots and regulator.
- Tag and disengage the injector electrical connectors.
- Remove the fuel injectors from the lower intake manifold assembly, then remove and discard the old O-rings.
Because each injector is calibrated for a specific flow rate, make sure you only replace fuel injectors using an IDENTICAL part number to the old injectors.
- Lubricate the new O-ring seals with clean engine oil, then position them on the injectors.
- Carefully install the injector assemblies into the lower manifold sockets, making sure the electrical connectors are facing inward.
- Install the injector bracket so that the injector retaining slots and regulator are aligned with the bracket slots.
- Engage the injector electrical connectors as tagged during removal.
- Install the fuel pressure regulator assembly.
- Make sure the threads of the injector retainer bracket screws are coated with a suitable threadlocking compound, such as Loctite®262 or equivalent, then install and tighten them to 31 inch lbs. (3.5 Nm).
- Install the upper intake manifold assembly. Please refer to the procedure in Engine & Engine Overhaul of this repair guide.
- If not done already, install the accelerator cable bracket. Tighten the retaining nut to 22 ft. lbs. (30 Nm) and the retaining bolts to 18 ft. lbs. (25 Nm).
- Connect the negative battery cable.
- Pressurize the fuel system by cycling the ignition (without attempting to start the engine), then check for leaks.
- If not done already, install the air inlet duct.
See Figure 3
- Relieve the fuel pressure.
- Disconnect the negative battery cable.
- Remove the air intake duct.
- Remove the throttle body for extra working room.
- Label and disconnect the harnesses from the fuel injectors.
- Disconnect the fuel lines from the fuel rail.
- Clean up any fuel that spilled on the engine or intake manifold.
- Remove the fuel rail and injectors from the intake manifold as an assembly.
- Separate the fuel injectors from the fuel rail.
- Lubricate new O-rings with clean engine oil and install them onto the fuel injectors.
- Install the fuel injectors onto the fuel rail.
- Lubricate the fuel injector O-rings with clean engine oil and install them, along with the fuel rail, onto the intake manifold.
- Install the fuel rail mounting bolts and tighten them to 14 ft. lbs. (19 Nm).
- Connect the fuel lines to the fuel rail using new sealing washers.
- Connect the harnesses to the injectors.
- Install the throttle body with a new gasket, and tighten the mounting bolts to 14 ft. lbs. (19 Nm).
- Install the air intake duct.
- Connect the negative battery cable.
- Turn the ignition to the ON position to pressurize the fuel system. Then, check the injectors and fuel line fittings for leaks.
- After warming the engine up to normal operating temperature, check the operation of the throttle cable and adjust it if necessary.
See Figures 3 and 4
- Relieve the fuel system pressure.
- Disconnect the negative battery cable and reinstall the fuel pump fuse or relay.
- Remove the air cleaner assembly.
- Disconnect the accelerator pedal cable from the throttle body and bracket.
- Disconnect the charcoal canister hose from the vacuum pipe.
- Disconnect the air vacuum hose and booster hose from the common chamber.
- Disconnect the harnesses from the MAP sensor, charcoal canister vacuum switching valve, exhaust gas recirculation valve and intake air temperature sensor. Disconnect the engine ground cable.
- Disconnect the spark plug wires from the valve covers.
- Remove the ignition module assembly with the spark plug wires attached.
- Disconnect the vacuum hoses from the throttle body.
- Remove the throttle body mounting bolts. Then, remove the throttle body.
- Disconnect the PCV hose, fuel pressure control valve vacuum hose, evaporative emission canister purge hose and EGR valve assembly from the common chamber.
- Remove the common chamber from the intake manifold (six bolts, two nuts and three brackets).
- Disconnect the fuel feed and return hoses from the fuel rail. Unbolt the fuel rail brackets from the cylinder head cover.
- Disconnect the thermo sensor.
- Remove the fuel rail mounting bolts. Lift the fuel rail up with the injectors still attached. Remove the fuel rail and injector assembly from the vehicle.
- Slide the retainer clip sideways to remove each fuel injector from the fuel rail.
- Clean up any fuel that has spilled.
Always use new O-rings when assembling the fuel injectors and installing the fuel rail assembly to the intake manifold. Always use new sealing washers when reconnecting fuel lines.
- Lubricate new O-rings with engine oil and install them on the fuel injectors.
- Install the fuel injectors onto the fuel rail and secure with the retaining clips.
- Install the fuel rail to the intake manifold. Make sure the injectors are securely seated into the manifold ports.
- Connect the harnesses to the fuel injectors and the thermo sensor.
- Connect the fuel return and feed hoses to the fuel rail.
- Install the common chamber. Tighten the bolts and nuts in a crisscross pattern to 17 ft. lbs. (23 Nm).
Replace any gaskets between the throttle body, common chamber, and intake manifold to prevent the possibility of leaks.
- Install the EGR assembly. Tighten the bolts to 78 inch lbs. (9 Nm).
- Connect the charcoal canister purge hose, fuel pressure regulator vacuum hoses and PCV hose to the common chamber.
- Install the throttle body assembly and connect the vacuum hoses to the throttle body. Tighten the throttle body mounting bolts to 16 ft. lbs. (22 Nm).
- Install the ignition module assembly. Tighten the mounting bolts to 16 ft. lbs. (22 Nm).
- Reconnect the spark plug wires.
- Connect the MAP sensor, charcoal canister vacuum switching valve, exhaust gas recirculation valve, intake air temperature sensor and engine ground cable.
- Connect the air vacuum and vacuum booster hoses to the common chamber.
- Connect the charcoal canister vacuum hose to the vacuum pipe.
- Connect the accelerator cable to the throttle body and bracket.
- Install the air cleaner and reconnect the negative battery cable.
- Turn the ignition key to the ON position for two seconds, then OFF . Turn the ignition ON again to pressurize the fuel system and check for leaks where the fuel system was disconnected.
See Figures 5 and 6
- With the engine running, listen to the injector noise with a stethoscope. Normal operation is indicated when a regular click, which varies with engine speed, is heard. If a regular click is not heard, the injector is probably malfunctioning.
- To check if the injector is receiving its pulse signal, use a noid light. Simply unplug the connector and install the light, then crank the engine. If the light pulses, the injector is receiving its signal from the ECM.
- The injector may also be checked with a fuel injector tester. This tool substitutes the signal from the ECM to pulse the injector. Follow the tool manufacturer's instructions to test the injector.