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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 Pump Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
WARNING: Fuel/gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.
WARNING: Wear safety glasses in order to avoid eye damage.
CAUTION: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution .
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief 
  2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (without KL9)Battery Negative Cable Disconnection and Connection (with KL9)
  3. Use the crankshaft balancer absorber bolt (1) to turn the crankshaft balancer absorber until the markings (2, 3) line up. Ensure cylinder 1 is at top dead cylinder (TDC) of the combustion stroke.
    Fig 1: Crankshaft Balancer Alignment Marks
    GM3213250Courtesy of GENERAL MOTORS COMPANY
  4. Extend the TDC marking (1).
    Fig 2: TDC Marking
    GM3288719Courtesy of GENERAL MOTORS COMPANY
  5. Turn the crankshaft balancer absorber in the direction of engine rotation to 80 degrees (a) after TDC using the crankshaft balancer absorber bolt (1).
    Fig 3: Fuel Injection Pump Bolts
    GM3288720Courtesy of GENERAL MOTORS COMPANY
  6. Remove the fuel injection pump sound insulator (1). Refer to Fuel Injection Pump Sound Insulator Replacement 
    Fig 4: Fuel Injection Pump Sound Insulator
    GM4859594Courtesy of GENERAL MOTORS COMPANY
    WARNING: The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage and possible injury or death.
  7. Disconnect the fuel feed front pipe (1) from the fuel injection pump. Refer to Fuel Feed Front Pipe Replacement 
    Fig 5: Fuel Feed Front Pipe
    GM4859596Courtesy of GENERAL MOTORS COMPANY
  8. Remove and DISCARD the fuel injection fuel feed front pipe (1). Refer to Fuel Injection Fuel Feed Front Pipe Replacement 
    Fig 6: Fuel Injection Fuel Feed Front Pipe
    GM4859597Courtesy of GENERAL MOTORS COMPANY
  9. Remove the fuel injection pump bolts (1).
    Fig 7: Fuel Injection Pump Bolts
    GM4859598Courtesy of GENERAL MOTORS COMPANY
    CAUTION: Alternately loosen the fuel pump bolts one turn at a time until the pump is fully disengaged from fuel pump lifter follower. Trying to remove the pump bolts without even side-to-side loosening may result in pump plunger damage
  10. Remove the fuel injection pump (2).
    NOTE: Ensure that during removal of the fuel injection pump that the fuel injection pump shaft lifter roller does NOT fall apart.
  11. Remove the fuel injection pump shaft lifter roller (3).
    NOTE:
    • The fuel injection pump shaft lifter roller MAY remain in the cylinder head bore after removing the fuel pump.
    • If the fuel injection pump shaft lifter roller does NOT pull out of the cylinder head bore with the fuel pump, then remove it afterwards.
  12. Remove and DISCARD the fuel injection pump housing seal (1).
    Fig 8: Fuel Injection Pump Housing Seal
    GM4859599Courtesy of GENERAL MOTORS COMPANY
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