Fuel Injector: Service and Repair

Fuel Injector Removal.:

Fuel Injector Replacement.:

WARNING: DO NOT ALLOW SMOKING OR THE USE OF OPEN FLAMES IN THE AREA WHERE WORK IN THE FUEL SYSTEM IS TAKING PLACE. ANYTIME THE FUEL SYSTEM IS BEING WORKED ON, DISCONNECT THE NEGATIVE BATTERY CABLE, EXCEPT FOR THOSE TESTS WHERE BATTERY VOLTAGE IS REQUIRED.

WARNING: WHENEVER FUEL LINE FITTINGS ARE LOOSENED OR DISCONNECTED, WRAP A SHOP CLOTH AROUND FITTING WHILE CONNECTING GAUGE, TO COLLECT THE FUEL. PLACE CLOTH IN AN APPROVED CONTAINER.

FUEL INJECTOR REMOVAL

1. Disconnect negative battery terminal.

2. Remove the TBI air cleaner assembly.

3. Connect fuel gage bar kit SA9127E (or equivalent) to fuel pressure test port.

4. Install bleed hose into an approved container and open valve to bleed system pressure. After system pressure is bled, remove gauge from fuel pressure test port and recap it.

5. Disconnect electrical connector at fuel injector.

6. Remove injector retainer screw and retainer.
CAUTION: Use care in removing injector to prevent damage to the electrical connector and nozzle. The fuel injector is an electrical component, and should not be immersed in any type of liquid solvent or cleaner.

7. Using a smooth object as a fulcrum, place a screwdriver under the injector's ridge opposite the electrical connector end of fuel injector, carefully pry it out.
WARNING: Use proper eye protection when blowing screen with compressed air.

8. Remove upper and lower O-rings from injector and cavity and discard. Inspect fuel injector filter for any evidence of dirt and contamination. The filter can be cleaned using compressed air, but do not remove the screen from the injector. If any dirt or contamination is present, check for presence of dirt in fuel lines and/or fuel tank.

NOTE: If replacement of the fuel injector is necessary, be sure to replace the injector with an identical part. Injectors from other units can fit into the fuel meter body, but are calibrated for different flow rates.

INSTALLATION

1. Lubricate new upper and lower O-rings with clean engine oil and place the upper one on the injector and the lower one in the fuel meter body injector cavity. Ensure that the upper O-ring is in the groove and the lower one is properly installed in the fuel meter body cavity.

2. Install the fuel injector assembly, pushing it straight into the fuel injector cavity.
NOTE: Make sure that the electrical connector end of the injector is facing toward the fuel pressure regulator.

3. Apply SATURN P/N 21485277 (Loctite 242 or equivalent), on the retainer attaching screw threads. Install the injector retainer and attaching screw.
^ Torque: 3 Nm (35 in lbs)

4. Connect electrical connector to the fuel injector. Push the injector electrical connector in until a click is heard and pull back on connector to confirm a positive engagement.

5. Connect negative battery terminal.

6. Prime fuel system.
a. Cycle ignition "ON" for 5 seconds and then "OFF" for 10 seconds.
b. Repeat step 6a twice.
c. Crank engine until it starts (maximum starter motor cranking time is 20 seconds).
d. If engine does not start, repeat steps 6a - 6c.

7. With engine "OFF" and ignition "ON", pressurize the fuel system and check for fuel leaks.

8. Inspect air cleaner gasket, and replace if torn, deteriorated, or damaged. Install the air cleaner assembly. Attach air inlet and fresh air tubes.