How do you change the fuel injectors on the 2.4 engine? I looked around a little and I couldnt really find what I need. Basicly what do I do, what are the do's and donts?
cheers
I recently put a fuel pressure regulator on my 97 2.4, which is on the fuel rail over the fuel injectors. Here's what I did...
1. Disconnect the battery. You don't want to accidenly power up the fuel pump while the fuel rail is open.
2. Remove the ducts for the air intake, they're going to be in the way.
3. Disconnect the vacuum line that goes to the fuel pressure regulator.
4. Disconnect the connection to the cam sensor, the wire will be in the way.
5 There's 2 bolts that hold the silver fuel rail to the cylender head. Remove them.
6. Follow the fuel lines towards the driver's side of the car. There's a bracket that holds the fuel lines to the intake manifold. Remove that bolt.
7. Continue down the fuel lines to the side of the engine, there's another bracket holding the fuel lines. Remove the bolt that holds that bracket.
8. The wiring for the fuel injectors is connected to 1 main clip on top of the intake manifold, disconnect here rather than disconnecting each fuel injector.
9. Wiggle the fuel rail and pull up-and-towards the front of the car. There will be fuel spilled, so have rags handy and a fire extinguisher, just in case.
(I don't know how to release the pressure from the fuel line any other way, maybe someone here has a better way)
10. When you have the fuel rail removed, the injectors *should* still be attached to it with spring clips. If any are still in the engine, they come out by pulling up-and-toward the front of the car. They're only held in to the engine by o-rings and clamped down by the fuel rail. Now would be a good time to think about replacing your fuel pressure regulator, as everything you've just taken apart will have to be removed again if you want to change it. The fpr is held in with 2 bolts at the end of the fuel rail and is sealed with o-rings.
11. Replace the fuel injectors with your new ones on the fuel rail, and NEVER REUSE THE O-RINGS! They're only 1.30 per injector, why risk a fuel leak? Before you try to squeeze in the new fuel injectors, rub a little motor oil on the o-rings. They'll go in easier. Don't use WD-40, for some reason it felt like the o-rings swelled up from it and were impossible to get in.
12. You should now have the fuel injectors clipped into the fuel rail. Clean the holes where the injectors go back in and line-up all 4 over their holes. You'll have to wiggle it a little to get it to slide back in.
13. Replace all the bolts on the fuel line and fuel rail, reconnect the battery. *Important* Do not overtighten the bolt on the intake manifold! It's plastic and will crack!! Have someone turn the key to "run" but not try to start the car while you look at the fuel rail/injectors. This will run the fuel pump for a few seconds and you can look for leaks. If you've got a gusher, you probably cut an o-ring during installation and have to replace it.
14. If you've got no leaks, reconnect everything else, attach the vacuum like to the fpr and you should be done.
Why are you going to change your injectors?
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John Wilken
2002 Cavalier
2.2 Vin code 4
Auto
Well its not my car, its my friends. Thought id help her out and do it for her. Thanks
