Here's a general outline. Specific steps may vary slightly depending on your Malibu's exact model and engine. Consult a repair manual specific to your vehicle (Chilton's or Haynes are good options) for detailed instructions and diagrams. These instructions are for guidance only and should not replace a proper repair manual.
Tools Needed:
* Safety Glasses and Gloves: Essential for protecting yourself from fuel spills and sharp objects.
* Socket Set (Metric): Various sizes, including likely 10mm, 12mm, 13mm, and possibly larger.
* Wrench Set (Metric): May be needed for certain bolts or fittings.
* Screwdrivers (Phillips and Flathead): For various fasteners.
* Fuel Pump Disconnect Tool: This special tool helps disconnect the fuel lines safely; some people manage without, but this tool greatly reduces the risk of damage.
* Torque Wrench: Important to tighten bolts to the correct specifications to prevent leaks.
* Jack and Jack Stands: To safely lift and support the vehicle.
* Wheel Chocks: To prevent the vehicle from rolling.
* Fuel Line Disconnect Tool: (Sometimes included with the fuel pump disconnect tool)
* Clean Rags or Shop Towels: For cleaning up any fuel spills.
* New Fuel Pump: Make sure you get the correct one for your vehicle's engine.
* Fuel Filter: Consider replacing this while you're at it, as it's usually easily accessible.
* Bucket or container: To collect any spilled fuel.
* Pliers: Possibly needed for various small tasks.
General Steps (Consult your repair manual for precise details):
1. Disconnect the Negative Battery Terminal: This is the most important step for safety.
2. Release Fuel Pressure: The fuel system is under pressure. There are several ways to do this; your repair manual will detail the best method for your vehicle. One common method involves repeatedly turning the ignition key to the "on" position (without starting the engine) until the fuel pump stops running.
3. Access the Fuel Pump: This usually involves lowering the fuel tank, but the method varies considerably depending on model. Some models require removing the rear seat, others require dropping the tank partially or completely. Your repair manual will be critical here. This often involves removing bolts, disconnecting electrical connectors, and possibly disconnecting fuel and vent lines.
4. Disconnect Fuel Lines and Electrical Connections: Use the fuel line disconnect tools carefully to avoid damage or spills. Be prepared to handle some fuel spillage. Disconnect the electrical connector(s) to the fuel pump.
5. Remove the Fuel Pump Assembly: This usually involves removing a retaining ring or clamp holding the fuel pump in place.
6. Install the New Fuel Pump: Follow the steps in reverse order, ensuring that all connections are secure. If you replace the fuel filter, do so at this point.
7. Reinstall the Fuel Pump Assembly: Make sure everything fits snugly.
8. Reconnect Fuel Lines and Electrical Connections: Double-check all connections for leaks.
9. Raise and Secure the Fuel Tank (If Applicable): Carefully raise the fuel tank back into its proper position and secure it with all the necessary bolts.
10. Reconnect the Negative Battery Terminal:
11. Test the Fuel System: Start the engine and check for leaks. Listen for the fuel pump's priming noise. If the engine runs smoothly, the replacement was successful.
Important Safety Notes:
* Work in a well-ventilated area. Fuel fumes are flammable and dangerous.
* Never smoke near fuel.
* Dispose of used fuel properly.
* If you are not comfortable performing this repair, take your vehicle to a qualified mechanic. This is a complex job with potential for serious consequences if done incorrectly.
This is a general overview. Always refer to a repair manual specific to your 1997 Chevrolet Malibu for detailed instructions and diagrams. Improperly replacing the fuel pump can lead to serious problems, including engine damage and fire. If you're unsure about any step, seek professional help.
