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HOMESERVICE MANUALSCHEVROLET2002CAVALIER BASE, 4D SEDAN, 2.4 TREPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE PERFORMANCESYSTEMENGINE CONTROL SYSTEM TESTING & ENGINE COMPONENT TESTINGFUEL SYSTEMS (GASOLINE)INJECTOR LEAK TEST (1.9L)
2002 Chevrolet Cavalier Base, 4D Sedan, 2.4 T

Injector Leak Test (1.9L)

2002 Chevrolet Cavalier Base, 4D Sedan, 2.4 TSECTION Injector Leak Test (1.9L)
  1. Remove air induction tube and resonator.
  2. Relieve fuel system pressure. See FUEL SYSTEM PRESSURE RELIEF (SATURN) under BASIC FUEL SYSTEM CHECKS in BASIC DIAGNOSTIC PROCEDURES - CARS - EXCEPT PRIZM.
  3. Remove throttle cable from throttle cable support bracket.
  4. Remove upper power steering support brace.
  5. Connect Gauge Bar Set (SA9127E) to fuel pressure port.
    6. NOTE: Lay shop towels on intake manifold and cam cover to collect any fuel. Make sure the injectors are positioned to prevent fuel from being sprayed onto the engine. Make sure that the injector retaining clips are properly installed.
  6. Remove fuel feed line clip attachment nut.
  7. Remove fuel rail assembly attachment bolts and pull fuel rail back far enough so that the nozzles of the fuel injectors are visible but still in ports. Attach the fuel rail to the intake manifold with safety wire.
  8. Connect fuel pressure gauge bar to pressure adapter.
  9. Wipe the tips of the fuel injectors free of any fuel or debris and place a clean White towel directly under fuel injectors. The clean White towel must lightly contact each fuel injector tip. This will serve as an indicator of leaky fuel injectors by showing spots where fuel has leaked as well as block the injector ports from any debris that might enter.
    10. NOTE: Battery must be at a minimum of 12 volts when performing any fuel system test. Charge battery before proceeding if below 12 volts.
  10. Connect scan tool and turn ignition On.
  11. Energize fuel pump using scan tool and observe the fuel injector tips for leakage of fuel. If one or more of the White towels becomes wet with fuel after five minutes, replace the faulty fuel injector. It is very difficult to measure drops of fuel from a injector. Pressure gauge reading should be approximately 40-55 psi (276-379 kPa).
  12. Test assembly a minimum of two times.
  13. Install bleed hose from Pressure Test Adapter (309725) into an approved container and open valve to bleed system pressure. Once pressure is bled, remove fuel gauge adapter from the fuel pressure test port and recap it.
  14. Lubricate injector "O" rings with clean engine oil and install fuel rail assembly.
  15. Start engine and check for leaks.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.