Here's a general overview. Consult a repair manual specific to your 2004 Chevy Malibu Classic for detailed instructions and diagrams. Improper procedures can be dangerous.
Before You Begin:
* Disconnect the negative battery cable: This is crucial to prevent electrical sparks.
* Allow the fuel pressure to release: This usually involves running the engine until it stalls, several times or letting the vehicle sit a while after running. Consult your repair manual for the safest method. Do not attempt to bypass fuel system safety features.
* Obtain appropriate safety equipment: This includes safety glasses, gloves, and possibly a fire extinguisher. Work in a well-ventilated area.
* Gather necessary tools: You'll need jack stands, a fuel pump removal tool (often a special socket), wrenches (various sizes), possibly a fuel line disconnect tool, and possibly a fuel tank strap wrench.
General Steps (Consult your repair manual for precise details):
1. Raise and secure the vehicle: Use jack stands to safely lift the vehicle. Never work under a vehicle supported only by a jack.
2. Locate the fuel tank: It's usually located under the rear seat area or in the trunk.
3. Disconnect the fuel lines: Carefully disconnect the fuel lines from the fuel tank. They're usually connected with quick-connect fittings. Use a fuel line disconnect tool if needed to avoid damage or spills. Contain any spilled fuel immediately.
4. Disconnect the electrical connector: Unplug the fuel pump electrical connector.
5. Lower the fuel tank: This usually involves unbolting the fuel tank straps or support system. A fuel tank strap wrench can help loosen the straps. This step is usually the most labor intensive.
6. Access the fuel pump: Once the tank is lowered (partially or fully depending on design), you'll locate the fuel pump access plate on the top of the tank.
7. Remove the access plate: This will expose the fuel pump.
8. Remove the fuel pump: Use the fuel pump removal tool to carefully remove the pump assembly.
9. Reverse the process to reinstall: Carefully install the new fuel pump, ensuring everything is properly seated and connected. Reattach and secure the fuel tank and connect the fuel and electrical lines.
Important Considerations:
* Fuel fumes are dangerous: Work in a well-ventilated area, away from any ignition sources.
* Fuel spillage is dangerous: Be extremely careful to minimize fuel spillage.
* Improper installation can lead to serious problems: Follow the instructions in your repair manual meticulously.
Recommendation: If you're not comfortable performing this repair yourself, it's best to take your vehicle to a qualified mechanic. This is a more complex repair than many DIY car repairs. The cost of a professional repair might be less than the cost of a mistake.
