OEM 2002 Chevrolet Malibu Fuel Rail

2002 Chevrolet Malibu Fuel Rail Parts Questions & Experts Answers

• Q: How to replace the fuel rail assembly on 2002 Chevrolet Malibu?

  A: You should note the eight-digit id mark directly stamped on the left-hand Fuel Rail because it controls even cylinders 2, 4, and 6. It is crucial to place black o-rings above brown o-rings when installing the Fuel Injector o-rings even though they share the same dimensions due to their differing material compositions. The fuel passages stay contamination-free during servicing by using fittings caps together with hole plugs. The first task should involve reducing fuel system pressure before removing the upper Intake Manifold. To proceed with engine maintenance remove both engine fuel feed and return pipes from their positions at the Fuel Rail and Fuel Pressure Regulator and keep the o-rings for disposal. Begin by removing the coolant temperature sensor electrical connector through the first step. Afterwards, disconnect the main injector harness electrical connector and the hook up each Fuel Injector connector by freeing the release lock then pushing the locking tab. Pull the injector electrical harness away from the Fuel Rail. Begin by untightening the Fuel Rail retaining bolts then removing both the Fuel Rail assembly and the injector o-ring seals which should be discarded from injector spray tips. The installation of the new Fuel Rail assembly should include tipping it before installing the injectors and securing it with attaching bolts torqued to 10 n.m (89 lb in). Connect the electrical connector of the coolant temperature sensor while installing the injector electrical harness and joining the injector connectors with slide locks properly seated. The first step includes a connection of the main injector harness electrical connector then placement of new o-rings onto the fuel feed and return pipes before piping the fuel feed tube into position at the Fuel Rail using a 17 n.m (13 lb ft) torque. The fuel return pipe should connect to the Fuel Pressure Regulator after securing its nut to 17 n.m (13 lb ft). Install the upper Intake Manifold and fasten the negative Battery Cable before continuing. Perform the inspection for fuel leaks by turning the ignition on for 2 seconds followed by 10 seconds off then repeating on while checking for any escape of fuel.