Malibu, Malibu MAXX 2006-2008

Fuel Pump

Print

Removal & Installation



  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.  

 
label.common.footer.alt.autozoneLogo