How to Remove the Fuel Injectors on a 2004 Chevrolet Cavalier

The 2004 Chevy Cavalier was only offered with the 2.2-liter Ecotec four-cylinder engine that featured 22 mpg in the city and 33 mpg on the highway. The 2.2-liter has an individual injector for each cylinder and is computer controlled to turn on at just the right time for combustion. The fuel pressure at each injector is around 50-60 psi with the ignition key turned to "On" and the engine not running. To remove the fuel injectors, the fuel pressure regulator and fuel rail must also be removed.

Instructions

Removal

1

Lift the vehicle hood and support it with the hood prop rod. Open the fuse box panel on the drivers side of the engine bay and remove the relay for the fuel pump. Start the engine and allow it to run until it stalls to relieve the fuel pressure. Turn off the ignition key and remove it from the ignition.

2

Disconnect the negative battery cable.
Loosen the clamps for the air intake tube at the resonator and air cleaner with the screwdriver. Remove the air intake tube from the engine bay.

3

The bracket on the left side of the resonator that conceals the throttle cable has a large slot in it; look through the slot to locate the clamp screw for the air intake resonator. Loosen the clamp for the air intake resonator with the screwdriver.

4

Loosen the clamp for the hose that runs from the valve cover to the air resonator and disconnect the hose from the valve cover. Disconnect the vacuum hose on the leg that connects the resonator to the air intake tube. Disconnect the wiring harness for the intake air temperature sensor on the leg of the resonator. Lift the resonator off the throttle body and out of the engine bay.

5

Unplug the wire harness from each fuel injector and position them away from the fuel injectors. Remove the two fuel rail mounting studs with the socket and ratchet. Pull the fuel rail back and up to remove the fuel injectors from the engine. Rotate the fuel rail forward so that the fuel injectors point strait down and remove the fuel rail and injectors from the engine bay.

6

Inspect the fuel injector lower O-rings to make sure they were removed from the fuel injector ports with the fuel injector. If any of the lower O-rings remain in the fuel injector port, gently pop them out with a flat-tip screwdriver. If any of the fuel injector insulator cups were removed from the cylinder head with the fuel injector, replace them.

7

Pop the fuel injector retainer clip from around the fuel rail and upper portion of the fuel injector. Remove the fuel injector from the fuel rail. If the upper O-ring remains in the fuel rail, pop it out with the flat-tip screwdriver. Repeat this step for all fuel injectors to be replaced.

Installation

8

Position the fuel rail so that the injectors face straight down. Tilt the fuel rail slightly to align the fuel injectors with the fuel injector ports. Push the fuel rail down gently so that each fuel injector is seated into the cylinder head.

9

Press each wire harness pigtail into its respective injector. Pull on each harness lightly to ensure it's properly connected to the injector. Set the fuel pressure regulator into the opening on the fuel rail and install the mounting bolt. Tighten the pressure regulator mounting bolt to 89 inch-pounds with the torque wrench.

10

Set the air intake resonator over the throttle body and push down on it gently to properly seat it. Tighten the air resonator to throttle body clamp with the screwdriver through the slot in the accelerator bracket. Install the vent hose onto the valve cover and secure it with the vent hose clamp.

11

Reconnect the negative battery cable.
Install the fuel pump relay into the fuel pump relay slot in the fuse box. Install the fuse box lid. Turn on the ignition switch without starting the engine for 2 seconds and then turn it back off for 10 seconds. Turn the ignition back to the "On" position and inspect the fuel system for any leaks. Latch the vehicle hood.