This is a general guide, and specific steps might vary slightly depending on the engine (2.4L or 3.1L). Always consult a repair manual specific to your 1999 Chevy Malibu for detailed instructions and diagrams. This is especially important for locating the fuel pump access panel, which can vary slightly year to year and trim level.
Here's a general outline of the process:
1. Safety First: Disconnect the negative battery terminal. Allow the vehicle to sit for a few minutes to allow any residual pressure in the fuel system to dissipate.
2. Locate the Fuel Pump Access Panel: This is usually located under the rear seat, but it could be in the trunk depending on your specific model. You might need to remove the rear seat cushion or trim panels to access it.
3. Drain the Fuel Tank (Optional but Recommended): This makes the job easier and less messy. You can use a fuel siphon pump to remove most of the fuel. Be extremely careful with gasoline – it's highly flammable. Work in a well-ventilated area, away from any ignition sources.
4. Remove the Access Panel: Once located, carefully remove the access panel, paying attention to how it comes apart so you can reassemble it later. There might be bolts, clips, or a combination of both.
5. Disconnect the Electrical Connector: Locate the electrical connector for the fuel pump and carefully disconnect it. Take note of how it's connected for reassembly.
6. Disconnect the Fuel Lines: You'll likely need a fuel line disconnect tool to safely disconnect the fuel lines. These tools prevent the lines from breaking or leaking. Be prepared for some fuel spillage; have rags ready.
7. Remove the Fuel Pump Assembly: The fuel pump is usually held in place by a retaining ring or bolts. Carefully remove this to access the pump assembly. This often involves removing a retaining ring or several bolts.
8. Remove the Fuel Pump from the Assembly: The fuel pump is typically held in place by a retaining clip or ring. Gently pry it out, being careful not to damage it.
9. Install the New Fuel Pump: Carefully install the new fuel pump into the assembly, ensuring it's properly seated.
10. Reassemble the Fuel Pump Assembly: Reverse the steps of removal to reassemble the fuel pump assembly. Make sure the retaining ring or bolts are tightened securely.
11. Reconnect the Fuel Lines and Electrical Connector: Carefully reconnect the fuel lines, ensuring they are securely attached. Reconnect the electrical connector.
12. Reinstall the Access Panel: Replace the access panel, securing it with bolts or clips.
13. Reconnect the Battery: Reconnect the negative battery terminal.
14. Prime the Fuel System: Turn the ignition key to the "ON" position (don't start the engine) for a few seconds to allow the fuel pump to prime. Repeat this a few times.
15. Start the Engine: Start the engine and check for leaks around the fuel lines and pump assembly. Listen for unusual noises from the fuel pump.
Important Considerations:
* Fuel Pump Sender Unit: The fuel level sensor is often integrated into the fuel pump assembly. Ensure the new unit includes this, or you'll lose your fuel gauge functionality.
* Fuel Pressure: After installation, you might need a fuel pressure gauge to verify the system is working correctly.
* Professional Help: If you're not comfortable with this repair, take your vehicle to a qualified mechanic. Working on the fuel system is dangerous if not done properly.
This guide provides a general overview. Always consult a repair manual specific to your vehicle's year, make, and model for detailed instructions and safety precautions. Improper repair can lead to serious injury or damage.
