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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 >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
WARNING: Refer to Gasoline/Gasoline Vapors Warning .
WARNING: Refer to Safety Goggles and Fuel Warning .
CAUTION: When working on the fuel rail and fuel injectors, always maintain a clean work surface. Failure to maintain a clean work surface can result in contaminant on the injector seals and cause leaks.
  1. Fuel Injection Fuel Feed Front Pipe - Remove Fuel Injection Fuel Feed Front Pipe Replacement 
  2. Ignition Coil - Remove [4x] - Ignition Coil Replacement 
  3. Fuel Injection Fuel Rail Wiring Harness (1) - Disconnect
    Fig 1: Fuel Injection Fuel Rail Wiring Harness
    GM4339851Courtesy of GENERAL MOTORS COMPANY
  4. Retainer (2) - Unclip
  5. Fuel Injection Fuel Rail Bolt (1) - Loosen [4x]
    Fig 2: Fuel Rail Bolts
    GM2917592Courtesy of GENERAL MOTORS COMPANY
    NOTE: The fuel injection fuel rail bolts are retained in the fuel injection fuel rail assembly. Loosen the fuel injection fuel rail assembly bolts from the camshaft cover and cylinder head, leaving the bolts in the fuel injection fuel rail assembly.
  6. Fuel Injection Fuel Rail Bolt (2) - Loosen [2x]
  7. Fuel Injector Bolt (1) - Remove
    Fig 3: Fuel Injector Cylinder 1
    GM2917598Courtesy of GENERAL MOTORS COMPANY
    NOTE: Never loosen both bolts at the same time, doing so could cause leaks or malfunction after installation.
    NOTE: Use care to ensure the bolt does not fall into the cylinder head slot.
  8. EN-51146-1-6  demounting screw (2) @ EN-51146-1-1  support (1) Install and tighten 7 N.m (62 lb in)
    Fig 4: Continental MGE Demounting Screw
    GM2966367Courtesy of GENERAL MOTORS COMPANY
  9. EN-51146-1-1  support (1) Install and tighten 5 N.m (44 lb in)
    Fig 5: Support And Cylinder 1 Fuel Injector
    GM2918369Courtesy of GENERAL MOTORS COMPANY
  10. Fuel Injector Bolt (1) - Remove
    Fig 6: Fuel Injector Cylinder
    GM2918374Courtesy of GENERAL MOTORS COMPANY
  11. EN-51146-1-6  demounting screw (2) @ EN-51146-1-1  support (1) Install and tighten 7 N.m (62 lb in)
    Fig 7: Continental MGE Demounting Screw
    GM2966367Courtesy of GENERAL MOTORS COMPANY
  12. EN-51146-1-1  support (1) Install and tighten 5 N.m (44 lb in)
    Fig 8: Support And Cylinder 1 Fuel Injector
    GM2918377Courtesy of GENERAL MOTORS COMPANY
  13. Repeat steps 7 - 12 for the remaining 3 injectors.
  14. Fuel Injection Fuel Rail Bolt (1) - Loosen [4x]
    Fig 9: Fuel Rail Bolts
    GM2966405Courtesy of GENERAL MOTORS COMPANY
    NOTE: The fuel injection fuel rail bolts are retained in the fuel injection fuel rail assembly. Loosen the fuel injection fuel rail assembly bolts from the cylinder head, leaving the bolts in the fuel injection fuel rail assembly.
  15. EN-51146-1-2  plate (2) @ EN-51146-1-1  supports (4) - Install
    Fig 10: Plates And Supports
    GM2918368Courtesy of GENERAL MOTORS COMPANY
    NOTE: Ensure the arrow on the EN-51146-1-2  plate points towards the front of the vehicle.
  16. Plate Bolt (3) - Install and tighten [8x] 5 N.m (44 lb in)
    NOTE: Use a wrench (1) to counter hold the EN-51146-1-1  support (4)
  17. EN-51146-1-3  sliding hammer (1) @ EN-51146-1-2  plate (2) - Install [2x]
    Fig 11: Slide Hammers And Plate
    GM2918367Courtesy of GENERAL MOTORS COMPANY
  18. Use the EN-51146-1-3  sliding hammers to remove the fuel injection fuel rail assembly evenly.
    Fig 12: Removing Injectors
    GM2966354Courtesy of GENERAL MOTORS COMPANY
    NOTE: Ensure the injectors are removed evenly. Tilting of the injectors in the bore could cause damage to the injector tip resulting in leaks or malfunction after installation.
  19. Install the EN-51146-1-2  plate (1) with the fuel injector assembly to a bench vise (2).
    Fig 13: Plate Installed In Vise
    GM2918382Courtesy of GENERAL MOTORS COMPANY
    CAUTION: After removing the fuel rail and injector assembly, do not allow the weight of the assembly to rest on the fuel injectors. Always position the assembly on a clean work surface with the fuel injectors on top. Failure to follow this caution could cause leaks or malfunction after installation.
    CAUTION: Refer to Fuel Rail Removal Caution .
  20. EN-51146-2-5  calibration tool (2) @ Fuel Injector (1) Install [4x]
    Fig 14: Calibration Tools
    GM2966369Courtesy of GENERAL MOTORS COMPANY
    NOTE: The EN-51146-2-5  calibration tools are also used to protect the fuel injectors.
  21. Cover the fuel injector bores at the cylinder head to prevent the entry of dirt or debris.
  22. EN-51146-1-3  sliding hammer - Remove [2x]
  23. EN-51146-2-5  calibration tool - Remove [4x]
  24. Inspect all fuel injectors for damage.
  25. Use EN-51146-2-1  stylus (1) to remove the combustion seal (2) [2x]
    Fig 15: Combustion Seals And Stylus
    GM2918378Courtesy of GENERAL MOTORS COMPANY
    CAUTION: Always use the stylus from the EN-51146  fuel injector kit. Never use a metal tool in place of the stylus. Use of another tool can damage the fuel injector and may cause a leak.
  26. Repeat step 25 for the remaining 3 fuel injectors.
  27. Re-inspect all fuel injectors for damage.
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