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Home >> Chevrolet >> 2020 >> Malibu LS >> Repair and Diagnosis >> External Pages >> Different car >> Section 27 (Engine Controls And Fuel - 1.8L (LKN) - Repair Instructions) >> Repair Instructions >> Fuel Injection Fuel Rail Assembly Replacement >> Installation Procedure

Installation Procedure

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  1. Clean and inspect the fuel injectors and the fuel injection fuel rail. Do not remove the fuel injector from the fuel rail. Fuel Injector and Fuel Injector Bore Cleaning and Inspection
  2. GM2918343Courtesy of GENERAL MOTORS COMPANY

    EN-51146-2-2  mounting sleeve-long (2) @ Fuel Injector - Install

  3. Install a NEW fuel injector combustion seal (1) to the EN-51146-2-2  mounting sleeve-long (2).
  4. GM2918345Courtesy of GENERAL MOTORS COMPANY

    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).

  5. GM2966372Courtesy of GENERAL MOTORS COMPANY

    Use the EN-51146-2-6-1  slider outside (1) to install the fuel injector combustion seal (2) to the Fuel Injector (3).

  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. 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.

  15. GM2918347Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Pre-form the fuel injector combustion seals by hand prior to using the sizing tool.

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

  16. 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.

  17. Loosen the nut (2) of the EN-51146-2-4  pre-sizing tool.
  18. 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).

  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. GM2968075Courtesy of GENERAL MOTORS COMPANY

    EN-51146-2-5  calibration tool (2) @ Fuel Injector (1) - Install

  21. EN-51146-2-5  calibration tool (2) @ Fuel Injector (1) - Remove
  22. 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.

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

    • 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. GM2918386Courtesy of GENERAL MOTORS COMPANY

    EN-51146-2-5  calibration tool (2) @ Fuel Injector (1) - Install [4x]

  26. Remove the fuel injector assembly with the EN-51146-1-2  plate from the bench vise.
  27. GM2918404Courtesy of GENERAL MOTORS COMPANY
    NOTE:

    Use a wrench (4) to counter hold the EN-51146-1-1  support (3)

    Plate Bolt (1) - Remove [8x]

  28. EN-51146-1-2  plate (2) - Remove
    29. 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.

  29. GM2918395Courtesy of GENERAL MOTORS COMPANY

    EN-51146-1-1  support (2) @ Fuel Injector (3) - Remove

    30. NOTE:

    DO NOT reuse the old fuel injector bolt.

  30. Apply thread locker to the NEW fuel injector bolt (1). Adhesives, Fluids, Lubricants, and Sealers
    31. CAUTION:

    Refer to Fastener Caution .

  31. Install NEW fuel injector bolt (1) to the fuel injector (3) and tighten to 5 N.m (44 lb in).
  32. GM2918396Courtesy of GENERAL MOTORS COMPANY

    EN-51146-1-1  support (1) @ Fuel Injector (3) - Remove

    33. NOTE:

    DO NOT reuse the old fuel injector bolt.

  33. Apply thread locker to the NEW fuel injector bolt (2). Adhesives, Fluids, Lubricants, and Sealers
  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. Fuel Injector and Fuel Injector Bore Cleaning and Inspection
  37. GM2969109Courtesy of GENERAL MOTORS COMPANY

    Check the fuel injector rail assembly:

    • 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. 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.

    carefully Install the fuel rail assembly (1).

  40. Push the fuel injectors lightly into their seats.
  41. GM2966402Courtesy of GENERAL MOTORS COMPANY

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

  42. GM4339851Courtesy of GENERAL MOTORS COMPANY

    Retainer (2) - Install

  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. 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.

  46. Perform a fuel rail assembly leak test.
    1. Start the engine.
    2. Check the fuel system for escaping fuel.
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