Malibu, Malibu MAXX 2006-2008

Fuel Rail (Supply Manifold) & 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.  

3.5L 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 injectors
     

  6.  

To install:

  1. Install or connect the following:

    Fuel injectors 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.  

3.9L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
    NOTE
    An 8-digit identification number is stamped on the fuel rail. Refer to this number if servicing or part replacement is required.


    CAUTION
    In order to reduce the risk of fire and personal injury that may result from a fuel leak, always install the fuel injector O-rings in the proper position. If the upper and lower O-rings are different colors (black and brown), be sure to install the black O-ring in the upper position and the brown O-ring in the lower position on the fuel injector. The O-rings are the same size but are made of different materials.

  4.  
  5. Disconnect the fuel feed pipe from the fuel rail.
  6.  
  7. Disconnect any remaining electrical connectors.
  8.  
  9. Remove the upper intake manifold.
  10.  
  11. Remove the fuel injector harness connector bracket bolt from the intake manifold.
  12.  
  13. Disconnect the Camshaft Position (CMP) sensor electrical connector.
  14.  
  15. Remove the fuel rail bolts.
  16.  
  17. Remove the fuel rail.
  18.  
  19. Remove and discard the O-rings from the spray tip end of each injector.
    WARNING
    Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method.



    Click image to see an enlarged view

    Fig. Fuel injector

  20.  
  21. Remove the fuel injector retaining clip, if required.
  22.  
  23. Remove the fuel injector from the fuel rail, if required.
  24.  
  25. Remove and discard the fuel injector upper O-ring.
  26.  

To install:


NOTE
DO NOT reuse the fuel injector O-ring seals. Install new O-ring seals during assembly.

  1. Lubricate the new injector O-rings with clean engine oil.
  2.  
  3. Install the new fuel injector upper O-ring.
  4.  
  5. Install the fuel injector to the fuel rail, if required.
  6.  
  7. Install the fuel injector retaining clip, if required.
  8.  
  9. Lubricate the new lower injector O-rings with clean engine oil.
  10.  
  11. Install the fuel rail assembly into the intake manifold. Tilt the fuel rail assembly slightly to install the injectors.

    Click image to see an enlarged view

    Fig. Fuel rail installation 3.9L engine

  12.  
  13. Install the fuel rail bolts and tighten to 89 inch. lbs. (10 Nm).
  14.  
  15. Connect the CMP sensor electrical connector.
  16.  
  17. Position the fuel injector harness connector bracket to the intake manifold.
  18.  
  19. Install the fuel injector harness connector bracket bolt and tighten to 71 inch. lbs. (8 Nm).
  20.  
  21. Install the upper intake manifold.
  22.  
  23. Connect any remaining electrical connectors.
  24.  
  25. Connect the fuel feed pipe to the fuel rail.
  26.  
  27. Inspect for fuel leaks with the following procedure:

    Turn ON the ignition for 2 seconds.
     
    Turn OFF the ignition for 10 seconds.
     
    Turn ON the ignition.
     
    Inspect for fuel leaks.
     

  28.  

 
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