Malibu 2001-2005

Removal & Installation

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2.2L & 3.5L Engines



  1. Remove the fuel pump module assembly.
  2.  
  3. Release the fuel level sensor wiring harness from the molded-in tab on the pump module bowl.
  4.  
  5. Disconnect the fuel level sensor electrical connector from the pump module cover.
  6.  
  7. Depress the retaining tab on the sensor and begin to slide the level sensor away from the pump module.
  8.  
  9. Carefully slide the level sensor the rest of the way off of the pump module.

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    Fig. The removal and installation of the fuel level sensor-Malibu Maxx shown



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    Fig. The removal and installation of the fuel level sensor-Malibu Sedan shown

  10.  

To install:

  1. Carefully slide the fuel level sensor into the slots on the fuel pump module bowl. Secure the retaining tab on the sensor into the slot on the pump module bowl.
  2.  
  3. Connect the fuel level sensor electrical connector to the pump module cover.
  4.  
  5. Install the fuel level sensor wiring harness to the molded-in tab on the pump module bowl.
  6.  
  7. Install the fuel pump module assembly.
  8.  

3.1L Engines



  1. Remove the fuel sender assembly.
  2.  
  3. Remove the fuel pump electrical retaining clip at the top of the fuel sender assembly.
  4.  
  5. Disconnect the fuel pump and fuel level sensor electrical connector.

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    Fig. Depress the 3 tabs (1) securing upper fuel reservoir and slide upward until free of lower reservoir (2)

  6.  
  7. Depress the 3 tabs securing upper fuel reservoir and slide upward until free of lower reservoir.

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    Fig. Depress the tab on the fuel level sensor (1) while sliding up and out of the housing

  8.  
  9. Depress the tab on the fuel level sensor while sliding up and out of the housing.
  10.  
  11. Remove the retaining clip from the electrical connector.
  12.  
  13. Remove the fuel level sensor wires from the connector, taking care to note the location of the wires.
  14.  

To install:


NOTE
Make sure the wires are routed under the fuel level sensor. Make sure the tab locks in place.

  1. Install the fuel level sensor by sliding the fuel level sensor down the slots on the lower housing.
  2.  
  3. Slide the upper reservoir into the lower reservoir making sure the tabs lock.
  4.  
  5. Connect the 2 wires into the connector and lock the connector with the retaining clip.
  6.  
  7. Connect the fuel pump and fuel level sensor electrical connector and lock the connector with the retaining clip.
  8.  
  9. Install the fuel sender assembly.
  10.  

 
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