Fix It

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 systems pressure before performing this repair procedure. Unless otherwise noted, some steps do not require tools.

Instructions

Removing the Fuel Rail and Fuel Injectors

1

Relieve the fuel system pressure by removing the fuel cap.

2

Disconnect the negative cable from the battery with a wrench.

3

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.

4

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.

5

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.

6

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.

7

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.

8

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

9

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

10

Pull out the fuel rail/injector assembly.

11

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

12

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

13

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.

14

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

15

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

16

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.

17

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

18

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

19

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.

20

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

21

Start your Saturn and check for any fuel leaks.

The Chrysler Concorde was a full-size, four-door sedan with front-wheel drive manufactured from 1993 to 2004. The most common engine in the 1993 model was a six-cylinder 3.3-liter engine with fuel injection. The fuel injectors send fuel to the engine and are part of the fuel rail assembly. The majority of the fuel injector replacement procedure for a 1993 Concorde deals with removing and installing the fuel rail assembly from the engine.

Instructions

1

Disconnect the negative battery cable with a socket wrench to prevent the engine from starting during the procedure. Loosen the cap on the fuel tank to relieve the pressure in the fuel tank. Remove the cap for the fuel pressure test port on the fuel rail.

2

Place the open end of the hose on tool C-4799-1 into a container approved for gasoline. Connect tool C-4799-1 to the fuel pressure test port and open the valve on the tool. Allow the fuel to drain into the container to relieve the pressure in the fuel system. Disconnect tool C-4799-1 from the fuel pressure test port and replace the cap on the fuel pressure test port.

3

Detach the air plenum from the throttle body and the air cleaner. Hold the throttle in the open position, and remove the linkages for the cruise control and throttle body from the throttle shaft.

4

Detach the electrical connectors from the exhaust gas recirculation valve and manifold absolute pressure sensor. Disconnect the vacuum hoses from the positive crankcase ventilation valve and the fuel pressure regulator. Remove the brake booster hose and throttle body purge hose from the intake manifold.

5

Detach the electrical connectors from the throttle position sensor and the idle air control motor. Disconnect the mounting screws for the exhaust gas recirculation tube with a socket wrench and remove the tube from the upper intake manifold. Disconnect the mounting bolts for the intake manifold plenum and remove the plenum from the engine.

6

Detach the fuel line from the fuel rail by pushing the quick-disconnect fitting on the fuel line with Special Quick-Connect Fitting Tool 6751. Wrap shop towels around the fuel line and disconnect the fuel line from the fuel rail. Disconnect the clamp on the fuel line with a socket wrench and remove the fuel line from its bracket.

7

Turn the fuel injectors on the fuel rail towards the center of the engine, and detach the electrical connectors from the fuel injectors. Disconnect the mounting bolts for the fuel rail and lift the fuel rail directly up from the engine.

8

Remove the retainer clip for the fuel injector and pull the injector out of the fuel rail. Install new O-rings to the new fuel injector and apply a light coat of engine oil to the upper O-ring. Install the fuel injector onto the fuel rail and attach its retainer clip. Apply a light coat of engine oil to the nozzle end of the fuel injector.

9

Complete the installation of the fuel injectors by performing steps two through six in reverse sequence. Tighten the mounting bolts for the fuel rail to 16 ft. lbs. with a torque wrench. Torque the mounting bolts for the intake manifold plenum to 21 ft. lbs. Connect the negative battery cable with a socket wrench.

The Thunderbird was a series of luxury cars that Ford manufactured from 1955 to 2005. The 1995 model belongs to the tenth generation of this series, which was in production from 1989 to 1997. The 1995 Thunderbird was typically equipped with an eight-cylinder 4.6-liter engine with multi-point fuel injection. The procedure for wiring a fuel injector is the same for all Thunderbirds and Cougars with this engine.

Instructions

1

Remove the negative battery cable with a socket wrench. This prevents you from starting the engine and discharging fuel during the fuel injector installation. Remove the cap from the fuel tank to relieve the fuel tank pressure.

2

Remove the cap from the fuel pressure relief valve on the fuel rail. Connect fuel pressure gauge T80L-9974-A to the relief valve, and place the drain tube for the fuel pressure gauge into a container suitable for gasoline. Open the valve on the fuel pressure gauge to drain the fuel system. Disconnect the fuel pressure gauge from the relief valve, and replace the relief valve cap.

3

Detach the vacuum line from the fuel pressure regulator. Remove the fuel lines from the fuel rail, and unplug the electrical connectors from the fuel injectors. Disconnect the retaining bolts for the fuel rail assembly with a socket wrench, and remove the fuel rail from the fuel injectors. Pull the fuel injectors while gently rocking them back and forth to remove them from the intake manifold.

4

Coat a pair of new O-rings with light engine oil, and mount them on each fuel injector. Install the fuel injectors into their sockets on the intake manifold, and twist them back and forth gently to properly seat them.

5

Push the fuel rail down onto the fuel injectors, and ensure that you fully seat the injector O-rings into the caps on the fuel rail. Connect the retaining bolts for the fuel rail as you hold the fuel rail in position. Tighten the retaining bolts to between 71 and 106 inch-pounds with a torque wrench. Attach the fuel lines for the fuel rail, and connect the vacuum line to the fuel pressure regulator.

6

Connect the cable for the negative battery terminal with a socket wrench, and turn the ignition on to pressurize the fuel system. Correct any fuel leaks, and disconnect the negative battery terminal.

7

Attach the electrical connectors for the fuel injectors, and connect the negative battery terminal. Start the engine, and allow it to idle for two minutes. Turn the engine off, and correct any fuel leaks.

The Vortec engine is a line of gasoline engines made by General Motors for its trucks since 1988. These engines use a technology that creates a vortex of fuel and air in the combustion chamber to improve the mixture of air and fuel. The most common Vortec engine in a 1995 vehicle is the 4300, a six-cylinder 4.3-liter engine with multi-point fuel injection. The fuel injector replacement procedure is generally the same for all Vortec engines made before 1999.

Instructions

1

Disconnect the cable from the negative battery terminal with a socket wrench. Open the filler cap on the fuel tank to relieve the pressure in the fuel tank. Remove the air cleaner from the intake manifold.

2

Squeeze the two tabs on the fuel injectors electrical connector, and pull it straight up to disconnect the electrical wiring from the fuel injector. Disconnect the cover for the fuel meter with a socket wrench, and discard its gasket.

3

Lift the fuel injector from the fuel meter with tool No. J-26868, and remove the small O-ring from the fuel injector. Remove the fuel filter from the injector by twisting the fuel filter back and forth. Remove the large O-ring and washer from the injector cavity in the fuel meter.

4

Coat the new small O-rings in automatic transmission fluid, and install them to the nozzle end of the fuel injector. Place the new washer into the injector cavity of the fuel meter, so that it is flush with the top of the cavity.

5

Install the new fuel injector so the lug on its base aligns with the notch in the injector cavity. Push the fuel injector down to seat it within the injector cavity, and ensure the injectors electrical terminals are parallel to the shaft of the throttle.

6

Replace the gasket for the fuel meter cover, and fasten the cover with a socket wrench. Attach the electrical connector for the fuel injector. Start the engine and check for fuel leaks.

Ford produced an eight-cylinder, 7.3-liter diesel engine from 1995 to 2002. This engine was frequently turbocharged and typically appeared in heavier trucks, beginning with the 3/4-ton pickups. Each cylinder has its own fuel injector, which delivers fuel to that cylinder at high pressure. You can remove each fuel injector on a Ford 7.3-liter diesel engine independently of the other injectors without removing the fuel rail from the engine.

Instructions

1

Disconnect the valve cover with a socket wrench. Unplug the electrical connector from the fuel injector and disconnect the drain plugs on the oil rail. Disconnect the oil deflector by removing its mounting screw with a socket wrench. Disconnect the outboard retaining bolt for the fuel injector.

2

Place the fulcrum of the Injector Remover No. T94T-9000-AH1 above the cylinder head and below the fuel injectors hold-down plate. Attach the injector remover to the cylinder head with the remover screw for the injector remover. Tighten the screw until the fuel injector comes out of the injector bore.

3

Discard the copper washer on the fuel injector. Use the Rotunda Injector Sleeve Brush 104-00934-A to remove any sealant residue from the injector bore and clean the injector bore with a shop towel. Coat the new fuel injector in engine oil and install a new copper washer to the injector. Place the fuel injector into its bore.

4

Position the end of the Injector Replacer No. T94T-9000-AH2 below the fuel injector and above the hold-down plate. Align the threaded hole in the cylinder head with the hole on the injector replacer tool. Install the bolt for the injector replacer tool to fasten the tool to the cylinder head. Tighten the bolt to fully seat the fuel injector into the injector bore on the cylinder.

5

Install the oil deflector, fuel rail drain plug and oil rail drain plug with a torque wrench. Torque the oil deflector mounting bolt to 108 foot-pounds. Torque the drain plug for the fuel rail to 96 foot-pounds and torque the drain plug for the fuel rail to 53 foot-pounds. Attach the electrical connector for the fuel injector and replace the valve cover with a socket wrench.