How to Remove a Fuel Injector From a 1990 Chevy

Chevrolet produced 20 different models of vehicles in 1990. Many of the same engines were utilized across the product line, though the exact configuration within the engine compartment depended on the accessories installed as well as any engine modifications for the particular model. The fuel injected engines operate by providing pressurized fuel to the electronically controlled fuel injectors. An electrical pulse sent to the fuel injectors charges a solenoid to open the valve within the injector. Fuel then passes through the injector into the combustion chamber.

Instructions

Removal

1

Depressurize the fuel line. Locate the fuel-safety-cutoff switch and remove the electrical plug. The location of the switch is provided in the owner's manual. Turn the ignition key to the start position to engage the motor and reduce the fuel pressure in the lines. The engine will not start.

2

Disconnect the negative cable from the car battery. Push the cable into a position it will not accidentally bump the negative terminal and spark.

3

Disconnect the engine shroud, air intake tube, vacuum hoses and electronics which prevent access to the fuel injectors. Remove any other engine components preventing access to the fuel rail.

4

Unplug the fuel injector electronics from each of the fuel injectors. Move the plugs aside to allow access to the fuel injectors.

5

Unbolt the fuel rail from the engine. Two to three retaining bolts hold the rail in place during operation. Two rails exist on V-engine models, one for each side of the engine. For engines transversely mounted in the engine compartment, found on front-wheel drive vehicles, use socket extensions and universal joints to loosen and remove the bolts.

6

Pull the fuel rail from the top of the fuel injectors. Discard the O-rings which held the fuel injectors in the fuel rail.

Replacement

7

Remove any fuel injectors to be replaced. Pull the injector directly out of the injector mount hole. Rock the injector to free it from the hole, if stuck. Discard the O-ring on the bottom of any injector you intend to return to the engine.

8

Replace the O-rings on the injectors. Clean the O-ring seat on the top or bottom of the injector with a clean cloth and brake parts cleaner. Dab clean motor oil on your finger. Rub the motor oil on the whole surface of the new O-ring. Push the O-ring into position on the O-ring seat. Do not use tools on the O-ring, because small tears will result in failure of the O-ring once installed.

9

Push the injector into the engine injector seat. Pull the injector slightly to determine if the injector is properly seated. Correctly seated injectors resist removal. Lightly press down on the injector to return it to the fully seated position.

10

Connect the fuel rail to the injectors. Align all the injectors under the fuel rail ports and evenly press on the fuel rail to allow near simultaneous attachment. Fuel injectors which are fully seated will remain in the fuel rail port when the rail is lifted slightly.

11

Insert and tighten the retaining bolts securing the fuel rail to the engine. Connect the fuel injector electronics plugs to the respective fuel injector.

12

Replace any engine components removed to provide access to the fuel rail. Replace the electronics, vacuum lines, air intake tube and engine shroud.

13

Reconnect the fuel-safety-cutoff switch. Reconnect the car battery. Turn the ignition to the "On" position to pressurize the fuel line. Inspect the fuel rails for leaks. Start the engine.