Here's a general overview of the process. This is NOT a substitute for a repair manual:
1. Safety First:
* Disconnect the negative battery cable. This is crucial to prevent sparks and electrical shock.
* Work in a well-ventilated area. Fuel fumes are flammable and dangerous.
* Wear safety glasses and gloves.
2. Preparation:
* Gather your tools: You'll need a socket set (including metric and possibly SAE), wrenches, screwdrivers (Phillips and flathead), fuel line disconnect tools, a fuel pump pliers/wrench (may be needed), jack stands, jack, safety glasses, gloves, and possibly a fuel pressure gauge.
* Drain the fuel tank (partially). This will make the job significantly easier and reduce the risk of fuel spillage. You can use a fuel pump removal tool to help siphon fuel out.
* Locate the fuel pump access panel. This is usually located under the rear seat or in the trunk. Consult your repair manual for the exact location. You may need to remove some interior panels to access it.
3. Fuel Pump Access:
* Remove the access panel. This usually involves removing some screws or fasteners.
4. Disconnect Fuel Lines and Electrical Connections:
* Disconnect the fuel lines. Use fuel line disconnect tools to avoid damaging the lines. Be prepared for some fuel spillage. Have rags ready. IMPORTANT: Note which line goes where to avoid mistakes during reassembly.
* Disconnect the electrical connector. Carefully unplug the electrical connector from the fuel pump.
5. Remove the Fuel Pump:
* Remove the fuel pump retaining ring or bolts. This step varies greatly depending on your model. Some pumps are held in place by a retaining ring that needs special pliers to remove. Others have bolts. Your repair manual will show the specifics.
* Remove the fuel pump assembly. Gently lift the fuel pump assembly out of the tank. It may be attached to a mounting flange.
6. Install the New Fuel Pump:
* Inspect the new fuel pump. Make sure it matches the specifications for your vehicle.
* Install the new fuel pump assembly. Carefully lower the new fuel pump assembly into the tank.
* Reattach the retaining ring or bolts. Tighten according to your vehicle's specifications.
7. Reconnect Fuel Lines and Electrical Connections:
* Reconnect the electrical connector. Make sure it's securely connected.
* Reconnect the fuel lines. Ensure they are properly seated and secured. Double check that you connected them correctly.
8. Reinstall Access Panel and Test:
* Reinstall the access panel.
* Reconnect the negative battery cable.
* Start the vehicle. Check for leaks around the fuel lines and access panel. Let the vehicle run for a few minutes to make sure the fuel pump works correctly.
* Check for any error codes. Use an OBD-II scanner to check for any codes that may have been triggered during the process.
Important Considerations:
* Fuel pressure: You may need a fuel pressure gauge to check the pressure after installation to ensure the new pump is working correctly.
* Fuel pump strainer: Consider replacing the fuel pump strainer while you're at it. This is a relatively inexpensive part that often gets clogged and can damage the pump.
* Professional help: If you are not comfortable performing this repair yourself, it's best to take your vehicle to a qualified mechanic. Incorrect installation can be dangerous and lead to more costly repairs.
This information is a general guide. Always consult your vehicle's repair manual for the specific procedures and torque specifications for your year and model Chevy Malibu. Failure to follow proper procedures can result in damage to your vehicle or personal injury.
