Bottom Feed Port Fuel Injectors

GM Cavalier/Sunfire 1995-2000 Repair Guide

TESTING
REMOVAL&INSTALLATION
TESTING
The easiest way to test the operation of the fuel injectors is to listen for a clicking
sound coming from the injectors while the engine is running. This is accomplished
using a mechanic's stethoscope, or a long screwdriver. Place the end of the
stethoscope or the screwdriver (tip end, not handle) onto the body of the injector.
Place the ear pieces of the stethoscope in your ears, or if using a screwdriver, place
your ear on top of the handle. An audible clicking noise should be heard; this is the
solenoid operating. If the injector makes this noise, the injector driver circuit and
computer are operating as designed. Continue testing all the injectors this way.
CAUTION
Be extremely careful while working on an operating
engine, make sure you have no dangling jewelry,
extremely loose clothes, power tool cords or other
items that might get caught in a moving part of the
engine.

All Injectors Clicking

If all the injectors are clicking, but you have determined that the fuel system is the
cause of your driveability problem, continue diagnostics. Make sure that you have
checked fuel pump pressure as outlined earlier in this section. An easy way to
determine a weak or unproductive cylinder is a cylinder drop test. This is
accomplished by removing one spark plug wire at a time, and seeing which cylinder
causes the least difference in the idle. The one that causes the least change is the
weak cylinder.
If the injectors were all clicking and the ignition system is functioning properly,
remove the injector of the suspect cylinder and bench test it. This is accomplished
by checking for a spray pattern from the injector itself. Install a fuel supply line to
the injector (or rail if the injector is left attached to the rail) and momentarily apply
12 volts DC and a ground to the injector itself; a visible fuel spray should appear. If
no spray is achieved, replace the injector and check the running condition of the
engine.
One or More Injectors Are Not Clicking
See Figures 1, 2, 3 and 4

Fig. 1: Unplug the fuel injector connector

Fig. 2: Plug the correct noid light directly into

the injector harness connector

Fig. 3: If the correct noid light flashes while

the engine is running, the injector driver
circuit inside the PCM is working

Fig. 4: Probe the two terminals of a fuel

injector to check it's resistance

If one or more injectors are found to be not operating, testing the injector driver
circuit and computer can be accomplished using a noid light. First, with the engine
not running and the ignition key in the OFFposition, remove the connector from the
injector you plan to test, then plug the noid light tool into the injector connector.
Start the engine and the noid light should flash, signaling that the injector driver
circuit is working. If the noid light flashes, but the injector does not click when
plugged in, test the injector's resistance. resistance should be between 11-18
ohms.
If the noid light does not flash, the injector driver circuit is faulty. Disconnect the
negative battery cable. Unplug the noid light from the injector connector and also

unplug the PCM. Check the harness between the appropriate pins on the harness
side of the PCM connector and the injector connector. Resistance should be less
than 5.0 ohms; if not, repair the circuit. If resistance is within specifications, the
injector driver inside the PCM is faulty and replacement of the PCM will be
necessary.
REMOVAL & INSTALLATION
See Figures 5, 6, 7, 8, 9, 10 and 11
WARNING
Any time the injectors are removed for service,
always remove the fuel pressure regulator to drain
excess fuel, and prevent fuel from entering the
engine cylinders. Flooded cylinders could result in
engine damage.

Fig. 5: Cross-section view of a bottom feed

fuel injector

Fig. 6: Remove the fuel injector retainer

bracket attaching screws (arrows)

Fig. 7: Remove the bracket by carefully

sliding it off to clear the injector slots

Fig. 8: Unplug the injector electrical

connectors

Fig. 9: Remove the fuel injectors from the

lower intake manifold assembly

Fig. 10: Remove the injector O-rings and

discard them

Fig. 11: You may need to use a pick to

remove the O-rings as the are sometimes
hard to get a hold of

1. Relieve the fuel system pressure as outlined earlier.

2. Disconnect the negative battery cable.
3. Remove the upper manifold assembly.
CAUTION
To reduce the chance of personal injury, cover the
fuel line connections with a shop towel, when
disconnecting.

4. Disconnect the fuel return line retaining bracket nut and move the return line
away from the regulator.
5. Remove the pressure regulator assembly.
WARNING
Do not try to remove the injectors by lifting up on
the injector retaining bracket while the injectors are
still installed in the in the bracket slots or damage to
the bracket and/or injectors could result. Do not
attempt to remove the bracket without first
removing the pressure regulator.

6. Remove the injector retainer bracket attaching screws and carefully slide the
bracket off to clear the injector slots and regulator.
7. Detach the injector electrical connectors.
8. Remove the fuel injector(s), then remove and discard the O-ring seals.

CAUTION
To reduce the risk fire and personal injury, make
sure that the lower (small) O-ring of each injector
does not remain in the lower manifold. If the O-ring
is not removed with the injector, the replacement
injector, with new O-rings, will not seat properly in
the injector socket and could cause a fuel leak.

9. Cover the injector sockets to prevent dirt from entering the opening.
Each injector is calibrated with a different flow rate so be sure to replace the
injector with the identical part numbers.
To install:
10. Lubricate the new injector O-ring seals with clean engine oil and install on the
injector assembly.
11. Install the injector assembly into the lower manifold injector socket, with the
electrical connectors facing inward.
12. Carefully position the injector retainer bracket so that the injector retaining
slots and regulator are aligned with the bracket slots.
13. Attach the injector electrical connectors.
14. Install the pressure regulator assembly.
15. Install the injector retainer bracket retaining screws, coated with thread
locking material and tighten to 31 inch lbs. (3.5 Nm).
16. Install the accelerator cable bracket with the attaching bolts/nuts finger-tight
at this time.
WARNING
The accelerator bracket must be aligned with the
accelerator cam to prevent cable wear, which could
result in cable breakage.

17. Align the accelerator bracket as follows:

a. Place a steel rule across the bore of the throttle body, with one end in
contact with the accelerator bracket.
b. Adjust the accelerator bracket to obtain a 25/64 in. (9-11mm) gap
between the bracket and the throttle body.
c. Tighten the top bolt first and tighten all bolts/nuts to 18 ft. lbs. (25
Nm).
18. Tighten the fuel filer cap.
19. Connect the negative battery cable and turn the ignition ON for 2 seconds,
OFF for 10 seconds, then ON and check for fuel leaks.
20. Install the air intake duct.