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Home >> Chevrolet >> 2017 >> Malibu LS >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 5 (Engine Controls And Fuel - 1.8L (LKN) - Repair Instructions) >> Repair Instructions >> Fuel Injection Fuel Rail Assembly Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different variant/trim than selected.
  1. Clean and inspect the fuel injectors and the fuel injection fuel rail. Do not remove the fuel injector from the fuel rail. Refer to Fuel Injector and Fuel Injector Bore Cleaning and Inspection
  2. EN-51146-2-2  mounting sleeve-long (2) @ Fuel Injector - Install
    Fig 1: Combustion Seals
    GM2918343Courtesy of GENERAL MOTORS COMPANY
  3. Install a NEW fuel injector combustion seal (1) to the EN-51146-2-2  mounting sleeve-long (2).
  4. Use the EN-51146-2-6-1  slider outside (1) to push the fuel injector combustion seal (2) down onto the EN-51146-2-2  mounting sleeve-long (3).
    Fig 2: Installing Combustion Seals
    GM2918345Courtesy of GENERAL MOTORS COMPANY
  5. Use the EN-51146-2-6-1  slider outside (1) to install the fuel injector combustion seal (2) to the Fuel Injector (3).
    Fig 3: Installing Combustion Seals
    GM2966372Courtesy of GENERAL MOTORS COMPANY
  6. EN-51146-2-6-1  slider outside (1) @ EN-51146-2-2  mounting sleeve-long - Remove
  7. EN-51146-2-2  mounting sleeve-long @ Fuel Injector (3) - Remove
  8. EN-51146-2-3  mounting sleeve-short @ Fuel Injector (3) - Install
  9. Install a NEW fuel injector combustion seal to the EN-51146-2-3  mounting sleeve-short.
  10. Use the EN-51146-2-6-1  slider outside (1) to push the fuel injector combustion seal down onto the EN-51146-2-2  mounting sleeve-short.
  11. Use the EN-51146-2-6-1  slider outside (1) to install the fuel injector combustion seal to the Fuel Injector (3).
  12. EN-51146-2-6-1  slider outside (1) @ EN-51146-2-2  mounting sleeve-short - Remove
  13. EN-51146-2-3  mounting sleeve-short @ Fuel Injector (3) - Remove
  14. Before using the EN-51146 - 2 - 4  pre-sizing tool (1), check if the fuel injector limiter (2) is in the right position.
    Fig 4: Fuel Injector Limiter
    GM3621254Courtesy of GENERAL MOTORS COMPANY
  15. Push the EN-51146-2-4  pre-sizing tool (1) over the fuel injector (2).
    Fig 5: Pre-Sizing Tool And Fuel Injector
    GM2918347Courtesy of GENERAL MOTORS COMPANY
    NOTE: Pre-form the fuel injector combustion seals by hand prior to using the sizing tool.
  16. Tighten the nut (2) and counterhold at the spanner flat of the EN-51146-2-4  pre-sizing tool thread (1) until the measure (a) of 4.5 mm (0.177 in) is reached.
    Fig 6: Pre-Sizing Tool
    GM2918354Courtesy of GENERAL MOTORS COMPANY
  17. Loosen the nut (2) of the EN-51146-2-4  pre-sizing tool.
  18. Install the EN-51146-2-4-7  take off chassis (2) to the EN-51146-2-4  pre-sizing tool (3).
    Fig 7: Take Off Chassis And Pre-Sizing Tool
    GM2918355Courtesy of GENERAL MOTORS COMPANY
  19. Install the EN-51146-2-4-6  screw M10 (1) to the EN-51146-2-4-7  take off chassis (2) and tighten until the EN-51146-2-4  pre-sizing tool (3) is loosened.
  20. EN-51146-2-5  calibration tool (2) @ Fuel Injector (1) - Install
    Fig 8: Calibration Tool And Fuel Injector
    GM2968075Courtesy of GENERAL MOTORS COMPANY
  21. EN-51146-2-5  calibration tool (2) @ Fuel Injector (1) - Remove
  22. Check the fuel injector combustion seals (2 seals each fuel injector) for correct seat:
    Fig 9: Installing Seal
    GM2918356Courtesy of GENERAL MOTORS COMPANY
    WARNING: The fuel injector seals must fit properly in the relative groove. Overlapping of the fuel injector seals with the external surface of the injector must be avoided. If the seals are installed incorrectly, it could cause leaks and risk of injury.
    • The seal must not be too large, buckled or corrugated (1).
    • The seal must be fixed tight and accurate (2).
  23. If the seals are installed not correctly, repeat the steps 24 - 27 of the removal procedure and the steps 1 - 22 of the installation procedure.
  24. Repeat 1 - 23 of the installation procedure for the remaining fuel injectors.
  25. EN-51146-2-5  calibration tool (2) @ Fuel Injector (1) - Install [4x]
    Fig 10: Calibration Tools And Fuel Injectors
    GM2918386Courtesy of GENERAL MOTORS COMPANY
  26. Remove the fuel injector assembly with the EN-51146-1-2  plate from the bench vise.
  27. Plate Bolt (1) - Remove [8x]
    Fig 11: Plate, Bolts And Supports
    GM2918404Courtesy of GENERAL MOTORS COMPANY
    NOTE: Use a wrench (4) to counter hold the EN-51146-1-1  support (3)
  28. EN-51146-1-2  plate (2) - Remove
  29. EN-51146-1-1  support (2) @ Fuel Injector (3) - Remove
    NOTE: Never loosen both EN-51146-1-1  supports at the same time. Doing so could cause leaks or malfunction after installation. It is only possible, when the fuel injector will be replaced.
    Fig 12: Support, Fuel Injector And Bolt
    GM2918395Courtesy of GENERAL MOTORS COMPANY
  30. Apply thread locker to the NEW fuel injector bolt (1). Refer to Adhesives, Fluids, Lubricants and Sealers
    NOTE: DO NOT reuse the old fuel injector bolt.
  31. Install NEW fuel injector bolt (1) to the fuel injector (3) and tighten to 5 N.m (44 lb in).
    CAUTION: Refer to Fastener Caution .
  32. EN-51146-1-1  support (1) @ Fuel Injector (3) - Remove
    Fig 13: Support, Fuel Injector And Bolt
    GM2918396Courtesy of GENERAL MOTORS COMPANY
  33. Apply thread locker to the NEW fuel injector bolt (2). Refer to Adhesives, Fluids, Lubricants and Sealers
    NOTE: DO NOT reuse the old fuel injector bolt.
  34. Install a NEW fuel injector bolt (2) to the fuel injector (3) and tighten to 5 N.m (44 lb in).
  35. Repeat the steps 29 - 34 for the remaining injectors.
  36. Clean the fuel injector bores at the cylinder head. Refer to Fuel Injector and Fuel Injector Bore Cleaning and Inspection
  37. Check the fuel injector rail assembly:
    Fig 14: Decoupling Elements And Retainers
    GM2969109Courtesy of GENERAL MOTORS COMPANY
    • Check the fuel injectors for damage.
    • Check the fuel injector seals for correct seating.
    • Check if all bolts (3) with decoupling elements (1) and retainer (2) are complete.
  38. EN-51146-2-5  calibration tool (2) @ Fuel Injector (1) - Remove [4x]
  39. Carefully Install the fuel rail assembly (1).
    Fig 15: Fuel Rail Assembly
    GM2918365Courtesy of GENERAL MOTORS COMPANY
    CAUTION: During the installation of the fuel rail and injector assembly, ensure that the fuel injectors are positioned straight into the injector opening. Failure to follow this caution can tilt or bend the injectors and could cause leaks or malfunction after installation.
  40. Push the fuel injectors lightly into their seats.
  41. Tighten the 10 fuel rail bolts (1) in the sequence as shown to 10 N.m (89 lb in).
    Fig 16: Fuel Rail Bolts
    GM2966402Courtesy of GENERAL MOTORS COMPANY
  42. Retainer (2) - Install
    Fig 17: Fuel Injection Fuel Rail Wiring Harness
    GM4339851Courtesy of GENERAL MOTORS COMPANY
  43. Fuel Injection Fuel Rail Wiring Harness (1) - Connect
  44. Ignition Coil - Install [4x] Ignition Coil Replacement 
  45. Fuel Injection Fuel Feed Front Pipe - Install Fuel Injection Fuel Feed Front Pipe Replacement 
  46. Perform a fuel rail assembly leak test.
    WARNING: Fuel escapes - observe safety measures and national legislation. Failure to comply could result in personal injury.
    NOTE: Ensure that all work at the engine is finished.
    1. Start the engine.
    2. Check the fuel system for escaping fuel.
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