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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 (2.2L SATURN)
2002 Chevrolet Cavalier Base, 4D Sedan, 2.4 T

Injector Leak Test (2.2L SATURN)

2002 Chevrolet Cavalier Base, 4D Sedan, 2.4 TSECTION Injector Leak Test (2.2L SATURN)
  1. Remove air cleaner inlet tube.
  2. Relieve fuel system pressure. See FUEL SYSTEM PRESSURE RELIEF (SATURN) under BASIC FUEL SYSTEM CHECKS in BASIC DIAGNOSTIC PROCEDURES - CARS - EXCEPT PRIZM.
  3. Connect Pressure Gauge Adapter (309725) to fuel pressure test port.
  4. Remove fuel line attachment screw and fuel lines from clamp.
    5. NOTE: Lay shop towels on intake manifold and cam cover to collect any fuel. Make sure the injectors a positioned to prevent fuel from being sprayed onto the engine. Make sure that the injector retaining clips are properly installed.
  5. Remove fuel rail assembly. Pull fuel rail back far enough so that nozzles of injectors are visible but still in ports. Attach fuel rail to intake manifold with wire.
  6. Connect fuel pressure gauge bar to pressure adapter.
  7. Wipe tips of fuel injectors free of any fuel or debris. Place a clean White towel directly under fuel injectors. Ensure towel lightly contacts each fuel injector tip.
  8. Connect scan tool and turn ignition On. Battery must be at a minimum of 12 volts when performing any fuel system test. Charge battery before proceeding if below 12 volts.
  9. Using the scan tool, energize fuel pump.
  10. Observe fuel injector tips for leakage of fuel. If one or more of White towels becomes wet with fuel after five minutes, replace faulty fuel injector. Pressure gauge reading should be approximately 50-60 psi (345-414 kPa).
  11. Test assembly a minimum of two times.
  12. Install bleed hose from Pressure Test Adapter (309725) into an approved container.
  13. Open valve to bleed system pressure.
  14. Remove fuel pressure adapter from fuel pressure test port.
  15. Install fuel pressure test port cap.
  16. Lubricate injector "O" rings with clean engine oil and install fuel rail assembly.
  17. Start engine and check for leaks.
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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.