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Home >> Chevrolet >> 2017 >> Malibu Hybrid >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Engine Controls And Fuel - 1.8L (LKN) - Repair Instructions >> Repair Instructions >> Fuel Injection Pump Replacement >> Installation Procedure

Installation Procedure

  1. Lubricate the NEW fuel injection pump housing seal (1) with clean engine oil and install it on the fuel injection pump. Refer to Adhesives, Fluids, Lubricants and Sealers
    Fig 1: Fuel Injection Pump Housing Seal
    GM4859599Courtesy of GENERAL MOTORS COMPANY
  2. Install the fuel injection pump bolts (1) through the fuel injection pump bolt retainers (2).
    Fig 2: fuel injection pump bolts
    GM4859600Courtesy of GENERAL MOTORS COMPANY
    NOTE:
    • ALWAYS make sure the fuel injection pump bolt retainers are present before installing the fuel injection pump bolts.
    • If ANY fuel injection pump bolt retainers are missing or NOT suitable for reuse. Replace the retainer(s) as necessary.
  3. Before continuing, lubricate the cylinder head bore with clean engine oil. Refer to Adhesives, Fluids, Lubricants and Sealers
  4. Lubricate the fuel injection pump shaft lifter roller (1) with clean engine oil and install it into the cylinder head bore. Refer to Adhesives, Fluids, Lubricants and Sealers
    Fig 3: Fuel Injection Pump Shaft Lifter Roller
    GM4859601Courtesy of GENERAL MOTORS COMPANY
  5. Install the fuel injection pump assembly (2) into the cylinder head and start the fuel injection pump bolts (3) by hand.
  6. Tighten the fuel injection pump bolts (3) to 11 N.m (97 lb in).
    CAUTION: Refer to Fastener Caution .
    CAUTION: Alternately hand-tighten the fuel pump bolts one turn at a time until the pump is fully seated. Trying to draw down the pump without even side-to-side tightening may result in pump plunger damage.
  7. Connect the fuel feed front pipe (1) to the fuel injection pump. Refer to Fuel Feed Front Pipe Replacement 
    Fig 4: Fuel Feed Front Pipe
    GM4859596Courtesy of GENERAL MOTORS COMPANY
  8. Install the NEW fuel injection fuel feed front pipe (1). Refer to Fuel Injection Fuel Feed Front Pipe Replacement 
    Fig 5: Fuel Injection Fuel Feed Front Pipe
    GM4859597Courtesy of GENERAL MOTORS COMPANY
  9. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (without KL9)Battery Negative Cable Disconnection and Connection (with KL9)
  10. Inspect for leaks using the following procedure:
    NOTE: The fuel injection pump electrical connector will have to be temporarily connected to perform the leak check. Afterwards, disconnect it to install the fuel injection pump sound insulator.
    1. Turn ON the ignition with the engine OFF for 2 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition with the engine OFF.
    4. Inspect for fuel leaks.
  11. Install the fuel injection pump sound insulator (1). Refer to Fuel Injection Pump Sound Insulator Replacement 
    Fig 6: Fuel Injection Pump Sound Insulator
    GM4859594Courtesy of GENERAL MOTORS COMPANY
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