OEM 2001 Chevrolet Malibu Fuel Rail

2001 Chevrolet Malibu Fuel Rail Parts Questions & Experts Answers

• Q: How to replace the fuel rail assembly on 2001 Chevrolet Malibu?

  A: The first step towards Fuel Rail assembly replacement requires locating the eight-digit identification code stamped onto the left-hand rail in service of even cylinders 2, 4, and 6. The correct o-ring installation order consists of black above brown since the o-rings differ in materials although they match in dimension. Service procedures require both fitting caps and fuel passage holes to be sealed off with appropriate plugs in order to stop contaminants from entering. Pressure relief of the fuel system should be performed first before upper Intake Manifold removal. The service requires disconnecting both the engine fuel feed pipe at the Fuel Rail and the engine fuel return pipe at the Fuel Pressure Regulator. When removing the components discard the o-rings from their respective pipes. Detach the main injector harness electrical connector as well as all Fuel Injector connectors by first pulling the lock release mechanism upward while depressing the lock tab downwards to remove the connectors from their installed positions. Detach the injector electrical harness from the Fuel Rail after unclipping the coolant temperature sensor electrical connector. Start by removing all Fuel Rail retaining bolts and extracting the Fuel Rail assembly afterward to obtain the injector o-ring seal from the spray tip end of each injector. Tilt the new Fuel Rail assembly to properly position the injectors before secure the rail with bolts that should be tightened to 10 n.m (89 lb in). Connect the Fuel Rail injector electrical harness to its component while ensuring slide locks are properly positioned. Then connect and secure the physical and electrical connectors of the Fuel Rail injector followed by the injector connectors. The main injector harness electrical connector needs to be connected back while technicians must install new o-rings on both the fuel feed pipe and fuel return pipe. Tighten the fuel feed pipe nut located at the Fuel Rail to 17 n.m while connecting the fuel return pipe at the Fuel Pressure Regulator by torquing the nut to 17 n.m (13 lb ft). To complete the procedure reinstall the upper Intake Manifold followed by reconnecting the negative Battery Cable and perform a fuel leak inspection through activating the ignition for 2 seconds followed by 10 seconds off and another 2 seconds on to identify any potential leaks.