The 2000 Chevrolet Malibu was available in a base model and an LS model. Both models were equipped with a 3.1-liter V-6 engine that produced 170 horsepower and 190 foot-pounds of torque. The fuel pressure regulator on the 2000 Malibu is responsible for maintaining the correct amount of pressure to the fuel injectors. A faulty fuel pressure regulator can cause a vehicle engine not to run or even start. Replacing the fuel pressure regulator requires attention to safety details.
Open the hood on the Malibu. Disconnect the negative battery cable from the battery. Locate the fuel pressure testing port on the top of the fuel rail and remove the small cap from the top of the port. Wrap a screwdriver tip in a towel. Insert the screwdriver tip into the port. Depress the pin in the center of the pressure testing port slightly to relieve the fuel pressure in the fuel lines. Allow the rag to absorb the fuel. Install the cap back onto the fuel pressure testing port.
Remove the fuel pressure regulator vacuum hose from the top of the fuel pressure regulator, which is located at the end of the fuel rail. Hold a rag beneath the regulator assembly to catch fuel that spills. Remove the mounting screw from the pressure regulator, using a Torx bit hand driver. Disconnect the fuel return line bottom of the fuel pressure regulator. Use an open-end wrench to remove the line from the bottom of the regulator.
Remove the old spacer and fuel pressure regulator retainer from the fuel rail, using pliers if needed. Install a new spacer and retainer onto the fuel rail.
Insert the return line onto the new pressure regulator and tighten the nut, using your open end wrench. It is important to install the line first, as twisting the fuel pressure regulator during installation can damage the regulator. Tighten the fuel return line nut to 13 foot-pounds, using a crowfoot attachment and a torque wrench. Install a new retainer and spacer onto the fuel rail, by hand. Install the fuel pressure regulator onto the fuel rail and tighten the screw to 76 inch-pounds, with a torque wrench and Torx bit socket. Reconnect the negative battery terminal.
Sit in the driver's seat. Turn the ignition key to the "Accessories" position without starting the engine. Turn the ignition key back to the "Off" position. Repeat this on and off process three times to completely pressurize the fuel lines and system. Turn the engine on and step out of the car. Inspect your work area near the fuel pressure regulator and underneath the vehicle for leaks. If a leak is spotted, turn the vehicle off immediately, locate the source and repair the leak.
