Malibu 2001-2005

Fuel Injectors

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Removal & Installation



2.2L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air intake assembly
     
    Vacuum hose from the fuel pressure regulator
     
    Fuel supply and return hoses
     
    Fuel injector harness connectors
     
    Fuel rail mounting studs
     
    Fuel rail
     
    Fuel injectors
     

  6.  

To install:

  1. Install or connect the following:

    Fuel injectors with new O-rings
     
    Fuel rail attaching studs. Tighten studs to 89 inch lbs. (10 Nm).
     
    Fuel injector harness connectors
     
    Fuel supply and return hoses
     
    Vacuum pipe to the fuel pressure regulator
     
    Air intake assembly
     
    Negative battery cable
     

  2.  
  3. Pressurize the fuel system and check for leaks.
  4.  

3.1L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:
    NOTE
    Be careful not to loose the O-ring backups.



    Accelerator cable from the throttle body lever and cable bracket
     
    Upper intake manifold
     
    Fuel feed line from the fuel rail and discard the O-ring
     
    Fuel return line from the fuel pressure regulator
     
    Main wiring harness connectors located near the alternator
     
    Coolant Temperature Sensor (CTS) electrical connector
     
    Fuel rail assembly
     
    Fuel injector electrical connectors
     
    Fuel injector-to-fuel rail clips
     
    Fuel injector(s)
     



    Click image to see an enlarged view

    Fig. Exploded view of the fuel rail assembly



    Click image to see an enlarged view

    Fig. Exploded view of the fuel injector

  6.  

To install:


NOTE
When installing new O-rings on the fuel injector, the lower position is color coded brown and the upper position is color coded black. Be sure to install the nylon O-ring backup to properly position the O-ring on the fuel injector so it doesn-t move when installing the fuel rail.

  1. Install or connect the following:

    Fuel injector with new O-rings
     
    Fuel injector electrical connectors
     
    Fuel rail assembly. Torque the bolts to 7 ft. lbs. (10 Nm).
     
    CTS electrical connector
     
    Main wiring harness connectors
     
    Fuel return line to the fuel pressure regulator using a new O-ring. Torque the fitting to 13 ft. lbs. (17 Nm).
     
    Fuel feed line to the fuel rail using a new O-ring. Torque the fitting to 13 ft. lbs. (17 Nm).
     
    Upper intake manifold
     
    Accelerator cable to the throttle body lever and cable bracket
     
    Fuel cap and tighten it
     
    Negative battery cable
     

  2.  
  3. Pressurize the fuel system and check for leaks.
  4.  

3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Fuel supply hose from fuel rail
     
    Upper intake manifold
     
    Main injector harness electrical connector
     
    Fuel injector electrical connectors
     
    Injector wiring harness from the fuel rail
     
    Fuel injector retaining clip
     
    Fuel injector(s)
     

  6.  

To install:

  1. Install or connect the following:

    Fuel injector(s) with new O-rings
     
    Fuel injector retaining clip
     
    Fuel rail assembly. Tighten the bolts to 89 inch lbs. (10 Nm).
     
    Injector wiring harness to the fuel rail
     
    Fuel injector electrical connectors
     
    Main fuel injector harness electrical connector
     
    Upper intake manifold
     
    Fuel supply hose to the fuel rail
     
    Negative battery cable
     

  2.  

 
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