Malibu 2001-2005

Fuel Pump

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the fuel tank.
  6.  
  7. Remove or disconnect the following:
    NOTE
    When removing the modular fuel sender from the tank, be aware that it may spring upward.


    CAUTION
    When removing the modular fuel sender from the tank, be aware that the reservoir bucket is full of fuel.



    Fuel tank
     
    Modular fuel sender assembly-to-fuel tank snapring by using fuel sender lock nut Tool J-39765, press down and rotate the cam lock ring until free of the fuel sender retaining tabs.
     



    Modular fuel sender assembly
     



    External fuel strainer
     
    Connector retainer from the wiring harness
     
    Fuel pump electrical connector
     

  8.  
  9. Gently release the tabs on the sides of the fuel sender at the cover assembly. Begin by squeezing the sides of the reservoir and releasing the tab opposite the fuel level sensor. Move clockwise to release the second and third tab in the same manner.
  10.  
  11. Remove or disconnect the following:

    Fuel pump/baffle assembly by rotating it counterclockwise
     
    Fuel pump by sliding the outlet away from the cover slots
     
    Fuel pump outlet seal
     

  12.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the fuel sender assembly mounting to the tank



Click image to see an enlarged view

Fig. Exploded view of the fuel pump assembly

  1. Install or connect the following:

    Fuel pump outlet seal
     
    Fuel pump outlet by sliding it into the reservoir cover slots
     
    Fuel pump/baffle assembly onto the reservoir retainer by rotating it clockwise until seated
     
    Lower retainer assembly by aligning the 3 sleeve tabs and pressing the retainer onto the reservoir until tabs are firmly seated
     
    Fuel pump electrical connector
     
    Connector retainer to the wiring harness
     
    External fuel strainer
     
    Modular fuel sender assembly
     
    Modular fuel sender assembly-to-fuel tank snapring using Tool J-39765
     
    Fuel tank
     
    Negative battery cable
     

  2.  
  3. Refill the fuel tank.
  4.  
  5. Pressurize the fuel system and verify no leaks.
  6.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the fuel tank.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Fuel tank
     
    Electrical and ventilation connections on the modular fuel sender assembly
     

  8.  
  9. Unlock the fuel sender lock ring using Special Tool J-45722 and a long breaker-bar.
  10.  
  11. Raise the fuel sender assembly out of the tank far enough to access the ventilation harness connection on the underside of the module.
    WARNING
    Be aware that the reservoir bucket on the sender assembly is full of fuel. It must be tipped slightly during removal to avoid damage to the float.

  12.  
  13. Disconnect the ventilation harness quick connector and remove the sender assembly.
  14.  

To install:


NOTE
If the lock ring is damaged, it must be replaced.

  1. Install a new O-ring on the modular fuel sender.
  2.  
  3. Connect the ventilation harness inside the tank to the bottom of the modular fuel sender.
  4.  
  5. Install the modular sender assembly and using Special Tool J-45722 install the fuel sender lock ring.
    NOTE
    Turn the lock ring until it seats on the second detent.

  6.  
  7. Install or connect the following:

    Electrical and ventilation connections on the modular fuel sender assembly
     
    Fuel tank.
     
    Negative battery cable
     

  8.  
  9. Refill the tank.
  10.  
  11. Pressurize the system and check for leaks.
  12.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the fuel tank.
  4.  
  5. Disconnect the fuel tank fuel pump module wiring harness electrical connectors from the fuel pressure sensor and the module.
  6.  
  7. Disconnect the fuel tank fuel pump module wiring harness electrical connector from the EVAP canister vent solenoid.
  8.  
  9. Remove the EVAP emission canister vent pipe from the retaining features built into the fuel tank.
  10.  
  11. Reposition the EVAP emission canister vent pipe enough in order to install the J 45722.
  12.  
  13. Install the J 45722 to the fuel pump module lock ring.
    NOTE
    Avoid damaging the lock ring. Use only J-45722 to prevent damage to the lock ring. Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended.


    WARNING
    Do Not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.



    Click image to see an enlarged view

    Fig. Installation of the J-45722 to the fuel pump module lock ring.

  14.  
  15. Using the J-45722 and a long breaker-bar, rotate the lock ring in a counterclockwise direction in order to unlock the lock ring.
  16.  
  17. Remove the J-45722 from the fuel pump module lock ring.
  18.  
  19. Lift the fuel pump module up slightly in order to disconnect the fuel tank vent pipe quick connect fitting from the module cover.
  20.  
  21. Raise the fuel pump module up from the fuel tank. Tilt the module in order to allow the fuel level sensor arm and float to clear the module opening.
  22.  
  23. Remove the fuel pump module.
  24.  
  25. Remove and discard the fuel pump module seal.
  26.  
  27. Clean the fuel pump module sealing surfaces.
  28.  

To install:


NOTE
Some lock rings were manufactured with DO NOT REUSE stamped into them. These lock rings may be reused if they are not damaged or warped. Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a new fuel pump module.

  1. Clean any contamination from the male pipe ends of the fuel pump module.
  2.  
  3. Place a new fuel tank module seal onto the fuel tank.
  4.  
  5. Insert the fuel pump module into the fuel tank allowing the sensor arm and float to clear the module opening.
  6.  
  7. Lower the module down into the fuel tank until the fuel tank vent pipe quick connect fitting can be connected.
  8.  
  9. Connect the fuel tank vent pipe quick connect fitting at the module cover.
  10.  
  11. Press the fuel tank module downward.
  12.  
  13. Reposition the EVAP emission canister vent line enough to install the J-45722.
  14.  
  15. Install the J-45722 to the fuel pump module lock ring.
    NOTE
    Ensure that the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.

  16.  
  17. Using the J-45722 and a long breaker-bar, rotate the lock ring in a clockwise direction in order the lock the lock ring.
  18.  
  19. Remove the J-45722 from the fuel pump module lock ring.
  20.  
  21. Install the EVAP emission canister vent pipe to the retaining features built into the fuel tank.
  22.  
  23. Connect the fuel tank fuel pump module wiring harness electrical connector to the EVAP canister vent solenoid.
  24.  
  25. Connect the fuel tank fuel pump module wiring harness electrical connectors to the fuel pressure sensor and the module.
  26.  
  27. Install the fuel tank.
  28.  

 
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