GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1999 🢒 Malibu 🢒 Engine 🢒 Engine Controls - 2.4L 🢒 Fuel Injector Replacement

Removal Procedure

    Object Number: 290215 Size: SH

    Caution: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury.

    After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.

  1. Relieve fuel system pressure. Refer to Fuel Pressure Relief Procedure .

    2. Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  2. Disconnect the negative battery cable.
  3. Remove the fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement .
  4. Remove the fuel injector retaining clip (1).

    5. Important: If the fuel injector is difficult to remove from the fuel rail assembly, useJ 43013 Multec II Injector Removal Tool.

    Important: Visually inspect the fuel injector to see if the upper O-ring was also removed, if not, remove the O-ring from the fuel rail assembly.

  5. Remove the fuel injector.

Installation Procedure

    Object Number: 290215 Size: SH

    Important:  Each fuel injector is calibrated for a specific flow rate. When replacing fuel injectors, be sure to order the correct fuel injector for the application being serviced.

  1. Lubricate new fuel injector O-ring seals (2) (3) with clean engine oil, and install on the fuel rail assembly .

    2. Important: When installing the fuel injector, care should be taken not to tear or misalign the fuel injector O-rings.

  2. Install the fuel injector upper O-ring (3).
  3. Install the fuel injector lower O-ring (2).
  4. Install the fuel injector to the fuel rail assembly.
  5. Install the fuel injector retaining clip (1).
  6. Install the fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement .
  7. Connect the negative battery cable.
  8. Inspect for leaks through the following steps:
    9. 8.1. Turn the ignition switch ON for 2 seconds.
    8.2. Turn the ignition switch OFF for 10 seconds.
    8.3. Turn the ignition switch ON.
    8.4. Check for fuel leaks.