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Re: removal of fuel tank 03 malibu
Before you do anything unplug your negative battery cable
1. raise vehicle put on jack stands 2. drain or siphon gas 3. remove bolts and straps connecting fuel tank to car 4. remove fuel lines and wires from top of fuel tank 5. reinstall is the exact same thing backwards 6. plan on spending about 2hrs. on removal and 2hrs on install
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drain fuel unhook battery take off cap jack up car remove screws inside fuel door loosen filler pipe support tank remove bolts from tank straps lower slowly unhook wires and hoses pump removal either screws or twist ring use something that wont cause a spark to twist ring off
This is caused by a defective fuel level sending unit inside the fuel tank. To repair the problem you must remove the fuel tank from the car and replace the fuel pump module which is part of the fuel level sensor.
Here's the procedure on how to install/replace fuel pump for your Chevy malibu.
•1 Raise the rear of the vehicle and place jack stands under the pinch welds on the lower body rocker panel. There are reinforced areas here that are designed to support the weight of the vehicle. Lower the car onto the jack stands and remove the floor jack. Unscrew the fuel filler cap to help relieve pressure that builds up in the tank due to fuel evaporation.
•2 Disconnect the plastic fuel lines leading from the tank to the front of the vehicle by pushing in on the line while depressing the quick disconnect fittings. Unplug the vapor return line and the fuel pump's electrical connector. Remove the fuel filler neck hose by loosening the hose clamps with a screwdriver and prying the hose loose with a large pry bar.
•3 Remove the two rubber exhaust system hangers located near the rear of the exhaust. This will allow the exhaust to move when removing the fuel tank. Remove the metal heat shield from the bottom of the car.
•4 Place the floor jack under the fuel tank, with a large flat piece of wood between the jack and the tank, and lift the tank slightly. This will take the weight of the tank off the straps attaching the tank to the undercarriage of the car. Remove the straps holding the tank to the body of the car, and lower the fuel tank. Slide the fuel tank past the exhaust system, and out from underneath the car.
•5 Remove the fuel pump assembly by turning the spring-loaded retaining ring with the hammer and chisel. Lift the whole assembly out of the fuel tank by lifting the assembly up and then rotating it over to clear the level sensor arm. Unsnap the top, and separate the plastic housing to gain access to the fuel pump. Remove the fuel pump electrical connector, and remove the pump from the assembly by pushing the pump up and over until it clears the assembly.
•6 Install the new pump into the assembly using the new rubber coupler and the new vibration cushion supplied with the pump. Plug the electrical connector into the new pump, and snap the two halves of the plastic housing back together. Install the assembly back into the tank, and rotate the spring-loaded retainer using the hammer and chisel.
•7 Reposition the tank under the car, and lift the tank into place with the floor jack. Install and tighten the retaining straps, heat shield and filler neck hose clamps. Reinstall the exhaust system hangers. Plug the electrical connector back into the assembly. Reconnect the fuel lines and vapor line.
•8 Lower the vehicle off the jack stands and prime the fuel system by cycling the ignition key from off to run a few times. Start the engine and check for leaks
The fuel "level" sending unit is located on the side of the fuel pump module, see red arrow on picture below. The fuel tank will need to be dropped and the fuel pump module removed in order to replace the fuel level sending unit. You can expect to pay a couple hours of labor to remove the tank and replace the level sending unit.
the fuel tank pressure sensor is located on top of the fuel pump module. The fuel tank will still need to be lowered to get at it but the fuel pump module does not need to be removed from the tank to replaced it.
1- remove fuel from tank, 2- take and loosen the tank straps, lower tank down far enough to disconnect the wiring and fuel lines.then lower tank to the ground. you may have to loosen the screws for the filler neck hose, inside of filler door to remove filler hose from tank. take off lock ring on fuel pump and pull pump out of tank, be carefull you may have to wiggle it out of tank as not to harm filter unless changing it. before starting on tank. disconnect battery as not to get any sparks. to install is reverse of removal.
It is inside the fuel tank. There is no access panel. The fuel tank has to be removed from the vehicle and slid out to the right side(to clear the exhaust on the left). Once the tank is out of the vehicle, the fuel module can be removed from the top of the tank.
the fuel pump should be under back seat after you remove seat lift carpet there is an access panel remove that next you should see ring that holds pump in tank spin this to remove unplug pump and replace
on 2000 malibu,the fuel pump is in the tank it will take you as long as it takes to drop tank! fuel pump is on top of tank,before starting remove fuel pressure by removing fuel pump fuse and run until it quits.it will take approx. 2-3hours to do a decent job. exhaust pipe is not on top it is on the left of the tank.