GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2008 🢒 Astra 🢒 Engine 🢒 Engine Controls and Fuel - 1.8L (2H0) 🢒 Fuel Injector Replacement

Special Tools

    • J 34730-1A /KM-J-34730-91 Fuel Pressure Gage
    • KM-807 Closure Plugs
    • J 37088-A Fuel Line Disconnect Tool Set

Removal Procedure
  1. Open the hood.

    2. Caution: Refer to Battery Disconnect Caution in the Preface section.

  2. Disconnect the battery.
    3. • Remove the ground connection from the negative terminal.
    • Loosen the nut.

    Object Number: 1945777 Size: SH
  3. Remove the engine venting pipe (1).
    4. • Remove the wiring (2) from the cylinder head cover.
    • Disconnect the 2 quick-release fittings.
  4. Remove the engine management wiring harness.
    5. • Disconnect the 9 wiring harness plugs.
       - Engine control module
       - Air mass flow meter
       - Tank vent valve
       - Throttle valve module
       - Valve, intake camshaft adjustment
       - Four injector valves
    • Remove the 2 wiring harness brackets.
    • Put the wiring harness to the side.
  5. Place a drain pan underneath.

    6. Caution: Refer to Gasoline/Gasoline Vapors Caution in the Preface section.

  6. Release the fuel pressure via the test connection (1) using J 34730-1A /KM-J-34730-91 .

    7. Collect the exiting fuel in a suitable container.


    Object Number: 1944873 Size: SH
  7. Remove the fuel return line (1).
    8. • Remove the quick-release fitting with J 37088-A .
    • Seal the fuel line and the fuel rail with KM-807 .

    Object Number: 1945797 Size: SH
  8. Remove the fuel rail (2).

    9. Remove the 2 bolts (1).


    Object Number: 1940561 Size: SH
  9. Remove the injectors.
    10. • Remove the 4 retaining clamps (1).
    • Pull out the 4 injectors.

Installation Procedure

    Important: Inspect the installation position and ensure correct fitting.

  1. Install the 4 injectors to the fuel rail.
    2. • Install the 4 new seal rings.
    • Coat the seal ring with silicone grease (white).
    • Install the 4 injection valves.
    • Install the 4 retaining clamps.

    Notice: Refer to Fastener Notice in the Preface section.

  2. Install the fuel rail.

    3. Tighten
    Tighten the 2 bolts to 8 N·m (71 lb in).

  3. Install the fuel supply line to the fuel rail.
    4. • Remove the 2  KM-807 .
    • Connect the quick release fitting.
    • Connect into the bracket.
  4. Install the engine management wiring harness.
    5. • Connect the 9 wiring harness plugs.
       - Engine control unit
       - Air mass flow meter
       - Tank vent valve
       - Throttle valve module
       - Intake camshaft actuator
       - Four injectors
    • Install the 2 wiring harness brackets.
  5. Install the engine vent hose.
    6. • Connect the 2 quick-release fittings.
    • Connect the wiring harness to the cylinder head.
  6. Connect the battery.

    7. Install the ground connection to the negative terminal.

    Tighten
    Tighten the ground connection nut to 5 N·m (44 lb in).

  7. For programming procedures, refer to Control Module References .
  8. Close the hood.