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Home › Chevrolet › 2010 › Malibu LS, 3.5 K › Repair and Diagnosis › Engine Performance › Engine Control Systems › Engine Controls And Fuel - 3.5L - Repair Instructions › Repair Instructions › Fuel Injection Fuel Rail Assembly Replacement › Installation Procedure

Installation Procedure

CAUTION:
  • Use care when servicing the fuel system components, especially the fuel injector electrical connectors, the fuel injector tips, and the injector O-rings. Plug the inlet and the outlet ports of the fuel rail in order to prevent contamination.
  • Do not use compressed air to clean the fuel rail assembly as this may damage the fuel rail components.
  • Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to the fuel rail assembly.
    Fig 1: Identifying Fuel Rail
    GM1557674Courtesy of GENERAL MOTORS CORP.
  1. Install NEW fuel injector O-ring seals onto the spray tip end of each injector, if the fuel rail was removed for other purposes.
  2. Install the fuel rail (1).
    3. CAUTION: Refer to Fastener Caution .
  3. Install the fuel rail bolts.

    Tighten:  Tighten the bolts to 10 N.m (89 lb in).

    4. Fig 2: Identifying Fuel Injector Wiring Harness Connector Bracket Bolt
    GM1775161Courtesy of GENERAL MOTORS CORP.
  4. Align the bracket pin to the hole in the lower intake manifold.
  5. Install the fuel injector wiring harness electrical connector bracket bolt to the intake manifold.

    Tighten:  Tighten the bolt to 14 N.m (10 lb ft).

    6. Fig 3: View Of Fuel Injector Wiring Harness Electrical Connector
    GM1775160Courtesy of GENERAL MOTORS CORP.
  6. Connect the fuel injector wiring harness electrical connector to the CMP sensor.
    7. Fig 4: View Of Upper Intake Manifold
    GM1775159Courtesy of GENERAL MOTORS CORP.
  7. Connect the fuel injector wiring harness electrical connector to the ECT sensor.
  8. Install the upper intake manifold. Refer to Upper Intake Manifold Replacement .
    9. Fig 5: View Of Fuel Feed & EVAP Pipes
    GM1774990Courtesy of GENERAL MOTORS CORP.
  9. Connect the fuel feed pipe quick connect fitting to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (LE5, LE9, LZ4, LZE, or LY7) .
  11. Tighten the fuel fill cap.
  12. Inspect for leaks.
    1. Turn ON the ignition, with the engine OFF for 10 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition for 10 seconds.
    4. Inspect for fuel leaks.
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