OEM 2003 Chevrolet Malibu Fuel Rail

2003 Chevrolet Malibu Fuel Rail Parts Questions & Experts Answers

• Q: How to service the fuel rail on 2003 Chevrolet Malibu?

  A: You should start by finding the eight-digit stamp on the left-hand Fuel Rail because this rail serves even-numbered cylinders 2, 4 and 6. A correct installation of Fuel Injector o-rings follows black o-ring placement above while brown o-ring placement must be below if o-rings possess different coloration since they are built with dissimilar materials yet share equivalent dimensions. Dirt and contaminants should be prevented from entering fuel passages through proper capping of fittings alongside plugging all service-related holes. The first step is to remove pressure from the fuel system before taking off the upper Intake Manifold. Remove and dispose of the o-rings from both the Fuel Rail and Fuel Pressure Regulator locations before disconnecting respective engine fuel pipes. To access the injector connectors users need to both disconnect the main injector harness electrical connector through the lock release mechanism and raise the lock tabs to pull the injector connectors free of their mounts. Start by removing the injector electrical harness from the Fuel Rail before disconnecting the coolant temperature sensor electrical connector and taking out the Fuel Rail assembly by removing its retaining bolts. Each injector must have its spray tip o-ring seal removed from its end. It is essential to handle the Fuel Rail installation method by securely plugging port inlets and outlets first to protect against contamination while keeping away from compressed air or Fuel Rail immersion in solvent baths. Adjust the Fuel Rail assembly before insertion into the Intake Manifold to install the injectors then proceed with tightening Fuel Rail bolts at 10 n.m (89 lb in). After reconnecting the coolant temperature sensor electrical connector it is necessary to install the injector electrical harness onto the Fuel Rail while joining injector connectors and verifying the slide locks are properly in place. First reconnect the main injector harness electrical connector then install new o-rings on the fuel feed pipe along with the fuel return pipe before connecting and tightening the fuel feed pipe at the Fuel Rail to 17 n.m (13 lb ft). Reinstall the upper Intake Manifold after you connect the fuel return pipe at the Fuel Pressure Regulator while tightening its nut to 17 n.m (13 lb ft). Before closing the system you must check for fuel leaks through a three-step test of turning on the ignition for two seconds followed by a ten-second off period then another on cycle for leak inspection.