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Home >> Chevrolet >> 2016 >> Malibu Hybrid >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Engine Controls And Fuel - 1.8L (LKN) - Repair Instructions >> Repair Instructions >> Fuel Injection Fuel Rail Assembly Replacement >> Installation Procedure

Installation Procedure

  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. Fig 1: Combustion Seals
    GM2918343Courtesy of GENERAL MOTORS COMPANY
  2. Install EN-51146-2-2  mounting sleeve-long (2) at Fuel Injector
  3. Install a NEW fuel injector combustion seal (1) to the EN-51146-2-2  mounting sleeve-long (2).
    4. Fig 2: Installing Combustion Seals
    GM2918345Courtesy of GENERAL MOTORS COMPANY
  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).
    5. Fig 3: Installing Combustion Seals
    GM2966372Courtesy 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).
  6. Remove EN-51146-2-6-1  slider outside (1) at EN-51146-2-2  mounting sleeve-long
  7. Remove EN-51146-2-2  mounting sleeve-long at Fuel Injector (3)
  8. Install EN-51146-2-3  mounting sleeve-short at Fuel Injector (3)
  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. Remove EN-51146-2-6-1  slider outside (1) at EN-51146-2-2  mounting sleeve-short
  13. Remove EN-51146-2-3  mounting sleeve-short at Fuel Injector (3)
    14. Fig 4: Fuel Injector Limiter
    GM3621254Courtesy of GENERAL MOTORS COMPANY
  14. Before using the EN-51146-2-4  pre-sizing tool (1), check if the fuel injector limiter (2) is in the right position.
    15. Fig 5: Pre-Sizing Tool
    GM2918347Courtesy of GENERAL MOTORS COMPANY
    NOTE:

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

  15. Push the EN-51146-2-4  pre-sizing tool (1) over the fuel injector (2).
    16. Fig 6: Pre-Sizing Tool
    GM2918354Courtesy of GENERAL MOTORS COMPANY
  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.
  17. Loosen the nut (2) of the EN-51146-2-4  pre-sizing tool.
    18. Fig 7: Take Off Chassis
    GM2918355Courtesy of GENERAL MOTORS COMPANY
  18. 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. Fig 8: Calibration Tool
    GM2968075Courtesy of GENERAL MOTORS COMPANY
  20. Install EN-51146-2-5  calibration tool (2) at Fuel Injector (1)
  21. Remove EN-51146-2-5  calibration tool (2) at Fuel Injector (1)
    22. 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.

  22. 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. Fig 10: Calibration Tools
    GM2918386Courtesy of GENERAL MOTORS COMPANY
  25. Install EN-51146-2-5  calibration tool (2) at Fuel Injector (1) (Qty: 4)
  26. Remove the fuel injector assembly with the EN-51146-1-2  plate from the bench vise.
    27. 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)

  27. Plate Bolt (1) (Qty: 8)
  28. Remove EN-51146-1-2  plate (2)
    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.

    Fig 12: Support
    GM2918395Courtesy of GENERAL MOTORS COMPANY
  29. Remove EN-51146-1-1  support (2) at Fuel Injector (3)
    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. Fig 13: Support
    GM2918396Courtesy of GENERAL MOTORS COMPANY
  32. Remove EN-51146-1-1  support (1) at Fuel Injector (3)
    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. Fig 14: Decoupling Elements And Retainers
    GM2969109Courtesy of GENERAL MOTORS COMPANY
  37. 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. Remove EN-51146-2-5  calibration tool (2) at Fuel Injector (1) (Qty: 4)
    39. 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.

  39. carefully Install the fuel rail assembly (1).
  40. Push the fuel injectors lightly into their seats.
    41. Fig 16: Fuel Rail Bolts
    GM2966402Courtesy of GENERAL MOTORS COMPANY
  41. Tighten the 10 fuel rail bolts (1) in the sequence as shown to 10 N.m (89 lb in).
    42. Fig 17: Fuel Injection Fuel Rail Wiring Harness
    GM4339851Courtesy of GENERAL MOTORS COMPANY
  42. Install Retainer (2)
  43. Connect Fuel Injection Fuel Rail Wiring Harness (1)
  44. Install Ignition Coil (Qty: 4) - Ignition Coil Replacement 
  45. Install Fuel Injection Fuel Feed Front Pipe - 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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