How to Replace a Fuel Injector in a Saturn

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If your Saturn is experiencing failing fuel injectors, you may want to consider using a better quality gasoline. Symptoms of faulty fuel injectors include jerking movements while driving and loud knocking sounds upon acceleration. You will need to know how to properly relieve the fuel system's pressure before performing this repair procedure. Unless otherwise noted, some steps do not require tools.

Things You'll Need

  • Wrench
  • Safety glasses
  • Socket wrench set
  • Open-end (combination) wrench set
  • Flat head screwdriver
  • New rubber O-rings
  • New fuel injectors
  • Clean engine oil
  • Torque wrench

Removing the Fuel Rail and Fuel Injectors

  • Relieve the fuel system pressure by removing the fuel cap.

  • Disconnect the negative cable from the battery with a wrench.

  • Remove the vacuum hose from the fuel pressure regulator on the fuel rail. Unbolt the two mounting bolts with a socket wrench then remove the regulator.

  • Disconnect the air intake duct by detaching the connector from the intake air temperature sensor then removing the PCV hose from the duct. Unscrew and remove the hose clamps with a flat head screwdriver at both ends of the duct.

  • Remove the EVAP canister purge hose and loosen the clamp for the coolant hose from the hose guide. Remove the hose guide and separate the PCV hose from the valve cover. Set aside the hoses.

  • Unscrew and remove the two nuts from the fuel rail mounting studs with the socket wrench. Remove the engine wiring harness cover from the valve cover and push it aside.

  • Remove the fuel supply and return lines from the fuel rail by unscrewing the two line fittings with an open-end wrench. Take out the O-rings in the holes and discard them.

  • Unplug the connectors from the fuel injectors by pulling on their locks.

  • Unscrew and remove the two fuel rail mounting nuts with the socket wrench.

  • Pull out the fuel rail/injector assembly.

  • Free the injector retainers from the small lugs on both sides with a flat head screwdriver. Pull each injector out.

Installing the New Fuel Injectors

  • Install the new fuel injectors and secure them onto the fuel rail by fastening the retainers back onto the side lugs.

  • Lubricate the O-rings on each end of the injectors with clean engine oil. Insert the fuel rail/injector assembly back into the intake manifold.

  • Install the fuel rail mounting nuts and torque them to 89 inch-pounds with a torque wrench.

  • Reconnect each electrical connector to the fuel injectors. Check to make sure they are securely locked on by slightly wiggling them.

  • Insert the new O-rings into the fuel line holes. Install the supply and return fuel lines onto the fuel rail and tightly screw on their fittings with the open-end wrench.

  • Position the engine wiring harness cover onto the valve cover. Tighten the mounting nuts over the studs with the socket wrench.

  • Follow Steps 4 and 5 in Section 1 to reconnect the EVAP and PCV hoses and the air duct.

  • Install the fuel pressure regulator onto the fuel rail and tighten its two mounting bolts with the socket wrench. Reattach the vacuum hose to the regulator.

  • Reconnect the negative cable onto the battery with the wrench. Replace the fuel cap.

  • Start your Saturn and check for any fuel leaks.

Tips & Warnings

  • To avoid clogged fuel injectors, try adding a fuel injection cleaner to the gas tank.
  • Be extremely careful when working on your Saturn's fuel system. Do not smoke or work around open flames.

References

  • Photo Credit pumping gas image by Mat Hayward from Fotolia.com
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