1997 Saturn SW2 AutomaticFACTORY OEM SERVICE PROCEDURE

Injector Leak Test

  1. Disconnect negative battery terminal. Remove air intake tube and resonator. Install Fuel Gauge Bar Kit (SA9127E) to fuel pressure test port. Bleed system pressure through bleed hose.
  2. Disconnect fuel pressure regulator vacuum hose. Remove fuel lines from bracket, leaving fuel supply lines attached to fuel rail assembly and connectors. Disconnect and plug fuel return line from fuel rail.
  3. Remove fuel rail assembly retaining bolts. Pull fuel rail back far enough so injector nozzles are visible but still in intake ports. Suspend fuel rail to intake manifold with wire.
  4. Wipe off any fuel or debris from fuel injector tips. Place a clean White towel directly under fuel injectors with towel lightly touching each fuel injector tip to easily spot a leaky injector.
  5. Reconnect negative battery terminal. Ensure battery is fully charged. Cycle ignition switch on and off several times. DO NOT start engine. Observe fuel injector tips for 5 minutes. Fuel rail pressure should be about 46 psi (3.23 kg/cm2 ) with fuel rail return line plugged. Run test at least twice. Replace any leaky fuel injector.
  6. Bleed fuel pressure through bleed hose and remove fuel pressure gauge. Reinstall fuel rail, fuel return line and pressure regulator vacuum hose. Lubricate injector "O" rings and male end of steel line with clean engine oil prior to installation. Start engine and check for fuel leaks.
Factory Service Tools

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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.

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