Here's a general outline of the process. Specific details may vary slightly depending on the exact engine and fuel system configuration:
1. Safety First:
* Disconnect the battery's negative terminal. This prevents accidental shorts and sparks.
* Work in a well-ventilated area. Fuel fumes are highly flammable.
* Wear safety glasses and gloves.
2. Preparation:
* Obtain the correct fuel pump. Ensure it's compatible with your engine and fuel system. You might need to provide the engine size and type when ordering a replacement.
* Gather necessary tools. You'll need wrenches (various sizes), sockets, a fuel line disconnect tool, possibly a fuel pump pliers, and possibly a pry bar.
* Drain the fuel tank. This will minimize the mess and the risk of fuel spillage. Consult your owner's manual for the proper procedure for draining the fuel tank.
* Locate the fuel pump. It's typically mounted on the engine block or near the fuel tank (depending on your model).
3. Removal of the Old Fuel Pump:
* Disconnect the fuel lines. Use a fuel line disconnect tool to avoid damaging the lines. Have rags ready to soak up any spilled fuel.
* Disconnect the electrical connector.
* Loosen and remove the mounting bolts. These may be difficult to access, depending on the location of the pump.
* Carefully remove the old fuel pump.
4. Installation of the New Fuel Pump:
* Install the new fuel pump gasket(s). Use a fresh gasket for a proper seal.
* Carefully align the new fuel pump with its mounting points.
* Tighten the mounting bolts to the manufacturer's specified torque. Over-tightening can damage the pump or its mounting.
* Reconnect the fuel lines. Make sure the lines are securely connected and tightened appropriately. Double check for leaks.
* Reconnect the electrical connector.
* Reconnect the battery's negative terminal.
5. Testing and Verification:
* Check for leaks. Inspect all connections for any leaks.
* Start the engine and let it run for a few minutes. Listen for any unusual noises coming from the fuel pump.
* Check the fuel pressure. You'll need a fuel pressure gauge to verify the pump is delivering the correct pressure. The specified pressure should be in your owner's manual or the fuel pump's documentation.
Important Considerations:
* Mechanical Fuel Pumps vs. Electric Fuel Pumps: 1966 Malibus likely used a mechanical fuel pump driven by the engine's camshaft. However, some conversions to electric pumps may have been done. The installation process differs significantly between these two types.
* Fuel Filter: It's a good idea to replace the fuel filter while you're working on the fuel system.
* Consult a Repair Manual: A factory service manual or a Haynes/Chilton repair manual specific to your 1966 Chevy Malibu is highly recommended. These manuals provide detailed instructions with diagrams.
This is a general guide. Always refer to a repair manual specific to your vehicle for precise instructions and torque specifications. If you lack the experience, seek professional help to avoid potential damage or injury.
