How to Replace Fuel Injectors in a 1996 Chev Cavalier

Problems within a fuel system, including poor acceleration or rough idle, can be caused by failing or clogged fuel injectors. Replacing fuel injectors in a 1996 Chevrolet Cavalier can end negative effects from faulty injectors. Novice mechanics can replace the injector themselves and save a trip to an authorized service center. 1996 Cavalier models have bottom-style fuel injectors that are directly seated in the intake manifold without an easily accessible fuel rail similar to later models.

Things You'll Need

• Socket set
• Screwdriver
• Torque wrench
• Ratchet wrench

Instructions

1. Relieve the fuel pressure. Remove the fuel-filler neck cap -- the cap removed when filling the gas tank -- and disconnect the fuel-pump electrical connector near the fuel tank underneath the car's rear. Run the car until all of the fuel burns off and the engine stalls.

2. Remove the air intake duct and air cleaner assembly -- this is the black plastic box -- and attached plastic duct on the driver's side of the engine compartment. Use a screwdriver to loosen the hose clamp holding the air intake duct to the throttle body and the clamp holding the duct to the air cleaner assembly. Disconnect the electrical connection to the intake air temperature sensor and the the wiring harness connectors on the air cleaner assembly. The IAT sensor is the only electrical connection on the air cleaner assembly, while the harness connectors attach the IAT sensor wiring to the air cleaner. Detach clips atop the air cleaner assembly and remove the top of the cleaner assembly and the air filter. Use a screwdriver to push the locking tabs toward the fender to unlock the lower portion of the cleaner from the body. Remove the cleaner assembly from the engine compartment.

3. Remove the accelerator cable on the throttle body in the center of the engine compartment. The cable looks like a small piece of dense wire located to a pedal controlling the throttle body. Slip the accelerator cable through the slot in the pedal arm.

4. Remove the vacuum distributor from the throttle body. The vacuum distributor is a rectangular-shaped, black plastic piece atop the throttle body. Pull the vacuum distributor up from the throttle body and set aside.

5. Disconnect the PCV hoses and power brake vacuum hoses. The PCV hoses are black hoses running from the top of the engine block to the large canister by the right from wheel. The brake vacuum hose runs from the top of the engine block to the brake master cylinder. The master cylinder is on the driver's side of the engine compartment near the firewall; it has a brake fluid reservoir directly atop it.

6. Disconnect the MAP, TPS and idle air control valve electrical connections. The manifold absolute pressure sensor is a rectangular-shaped black object on the back of the air intake plenum toward the firewall. The air intake plenum is the large metal top of the engine block. The throttle position sensor and the idle air control sensor are round, black plastic connections atop the throttle body. The IAC and TPS sensors are the only two electrical connections running to the throttle body.

7. Remove the power pump. Loosen and remove the power steering pump mounting bolts with a ratchet wrench. Remove the power-steering pump and set it aside without removing the attached hoses.

8. Remove the air intake plenum mounting bolts with a ratchet wrench and remove the air intake plenum from the engine compartment.

9. Unplug and label the fuel injector electrical connectors.

10. Remove the fuel injector bracket bolts with a ratchet wrench and remove the bracket.

11. Remove fuel injectors from the intake manifold. The injectors can be carefully removed using your hand.

12. Coat the seals on the new fuel injectors with a thin layer of engine oil. Seat the fuel injectors in the intake manifold.

13. Install the fuel injector bracket and tighten the bracket bolts with a torque wrench to 18 foot pounds.

14. Reconnect the fuel injector electrical connectors.

15. Install the air intake plenum and mounting bolts, tightening the bolts with a torque wrench to 22 foot pounds.

16. Install the power steering pump and mounting bolts with a ratchet wrench.

17. Connect the MAP, TPS and IAC electrical connections.

18. Connect the PCV hoses and power brake vacuum hoses.

19. Place the vacuum distributor back in to the throttle body.

20. Replace the accelerator cable. Slip the accelerator cable through the slot in the pedal arm.

21. Install the air intake duct and air cleaner assembly. Put the lower portion of the air cleaner back in place and engage the locking tabs. Place the air filter inside the lower portion of the assembly and place the upper portion over it. Connect the electrical connection to the IAT sensor and the the wiring harness connectors on the air cleaner assembly. Put the air intake duct in place and use a screwdriver to tighten the hose clamps connecting the duct to the throttle body and air cleaner assembly.

22. Install the fuel-filler neck cap and connect the fuel pump electrical connector near the fuel tank. Refill the gas tank with gas.

References

• "Haynes Repair Manual: Chevrolet Cavalier 1995 thru 2002"; John H Haynes, Rob Maddox and Mike Stubblefield; 2003