LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2020 >> Malibu LS >> Repair and Diagnosis >> External Pages >> Different car >> Section 19 (Engine Mechanical - 1.8L (LKN)) >> Repair Instructions - Off Vehicle >> Fuel Rail Installation >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2019 Chevrolet Malibu. However, it is still accessible from the selected car via links, so may be relevant.
  1. GM3764347Courtesy of GENERAL MOTORS COMPANY

    Install a NEW combustion fuel injector seal (1) to the EN-51146-2-2  mounting sleeve-long (2).

  2. GM2918345Courtesy of GENERAL MOTORS COMPANY

    Use the EN-51146-2-6-1  slider outside (1) to push down the combustion fuel injector seal (2) on the EN-51146-2-2  mounting sleeve-long (3).

  3. GM3764346Courtesy of GENERAL MOTORS COMPANY

    Push the combustion fuel injector seal (2) over the EN-51146-2-2  mounting sleeve-long, use the EN-51146-2-6-1  slider outside (1) to the fuel injector (3).

  4. Remove the EN-51146-2-2  mounting sleeve-long with the EN-51146-2-1  stylus from the EN-51146-2-6-1  slider outside.
  5. Install a NEW combustion fuel injector seal to the EN-51146-2-3  mounting sleeve-short.
  6. Use the EN-51146-2-6-1  slider outside to push down the combustion fuel injector seal on the EN-51146-2-2  mounting sleeve-short.
  7. Push the combustion fuel injector seal over the EN-51146-2-3  mounting sleeve-short, use the EN-51146-2-6-1  slider outside to the fuel injector.
  8. Remove the EN-51146-2-3  mounting sleeve-short with the EN-51146-2-1  stylus from the EN-51146-2-6-1  slider outside.
  9. GM3621254Courtesy of GENERAL MOTORS COMPANY

    Before using the EN-51146 - 2 - 4  pre-sizing tool (1), check if the fuel injector limiter (2) is in the right position.

  10. GM2918347Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    1st form the combustion fuel injector seals a bit with finger and thumb.

    Push the EN-51146-2-4  pre-sizing tool (1) over the fuel injector (2).

  11. GM2918354Courtesy of GENERAL MOTORS COMPANY

    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.

  12. Loosen the nut (2) of the EN-51146-2-4  pre-sizing tool.
  13. GM2918355Courtesy of GENERAL MOTORS COMPANY

    Install the EN-51146-2-4-7  take off chassis (2) to the EN-51146-2-4  pre-sizing tool (3).

  14. 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 loosed.
  15. GM2968075Courtesy of GENERAL MOTORS COMPANY

    Install the EN-51146-2-5  calibration tool (2) rotary to the fuel injector (1), as shown in the graphic.

  16. Remove the EN-51146-2-5  calibration tool from the fuel injector.
  17. GM2918356Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    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.

    Check the combustion fuel injector seals (2 seals per fuel injector) for correct seat:

    • The seal must not be to large, buckled or corrugated (1).
    • The seal must be fixed tight and accurate (2).
  18. If the seals are installed not correctly, repeat the steps 23 - 25 of the removal procedure and the steps 1 - 18 of the installation procedure.
  19. GM2918386Courtesy of GENERAL MOTORS COMPANY

    Install the 4 EN-51146-2-5  calibration tools (2) rotary to the fuel injectors (1).

  20. Remove the fuel injector assembly with the EN-51146-1-2  plate from the bench vise.
  21. GM2918404Courtesy of GENERAL MOTORS COMPANY

    Remove the 8 plate bolts (1) and remove EN-51146-1-2  plate (2), counterhold with a wrench (4) at the EN-51146-1-1  supports (3).

  22. GM2918395Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Never loosen both EN-51146-1-1  supports at the same time. Failure to follow this caution could cause leaks or malfunction after installation. It is only possible, when the fuel injector will be replaced.

    Remove one EN-51146-1-1  support (2) from the fuel injector (3).

    23. NOTE:

    DO NOT reuse the old fuel injector bolt.

  23. Apply thread lock agent to the NEW fuel injector bolt. Refer to Adhesives, Fluids, Lubricants, and Sealers .
    24. CAUTION:

    Fastener Caution

  24. Install NEW fuel injector bolt (1) to the fuel injector and tighten to 5 N.m (44 lb in).
  25. GM2918396Courtesy of GENERAL MOTORS COMPANY

    Remove the EN-51146-1-1  support (1) from the fuel injector (3).

    26. NOTE:

    DO NOT reuse the old fuel injector bolt.

  26. Apply thread lock agent to the NEW fuel injector bolt. Refer to Adhesives, Fluids, Lubricants, and Sealers .
  27. Install a NEW fuel injector bolt (2) to the fuel injector and tighten to 5 N.m (44 lb in).
  28. Repeat the steps 22 - 27 for the other 3 injectors.
  29. Clean the fuel injector bores at the cylinder head. Refer to Fuel Injector and Fuel Injector Bore Cleaning and Inspection .
  30. GM4175028Courtesy of GENERAL MOTORS COMPANY

    Check the fuel injector rail assembly:

    • Check the 4 fuel injector (5) for damage.
    • Check the 8 fuel injector seals (4) for correct seat.
    • Check if all bolts (3) with decoupling elements (1) and retainer (2) are complete.
  31. Remove the 4 EN-51146-2-5  calibration tools from the fuel injector.
  32. GM4248359Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    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.

    Fuel Injection Fuel Rail (1) - Install

  33. Push the fuel injectors slightly in their seats.
  34. GM4248360Courtesy of GENERAL MOTORS COMPANY

    Tighten the 10 fuel rail bolts (1) in the sequence as shown to 10 N.m (89 lb in).

scientia non olet · About LEMON Manuals