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eddie johnson Posted on Jan 10, 2014
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Replace fuel pump chevy - 2004 Chevrolet Malibu

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Larry Blais

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  • Expert 331 Answers
  • Posted on Mar 10, 2014
Larry Blais
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The fuel pump is inside the fuel sending unit. The sending unit is mounted on the topside of the fuel tank. There is a large O-ring that seal the sending unit to the tank (so gas does not leak out). This is a tedious job and requires the tank to be dropped. if the tank is full, the task of dropping the tank will be more dangerous. The fuel filler hose, fuel vapor hose, fuel supply line, fuel return line, and the electrical harness will need to be disconnected before you release both tank support straps. ***NOTE: the two fuel-lines coming off the sending unit are well designed to make them easy to remove. Personaly this design is one of my favorites. No special tools are needed to release the connections.***After the tank is slowly lowered onto the floor then you can start removing the sending unit. There is a round metal ring with four securing tabs. You will see a light blue plastic pin. This pin must be pulled/removed before the metal ring can be removed. NOTE: make sure your work area is clean, free of trip hazards, and no sparks or open flames. After the metal ring is removed, then the sending unit can be pulled out and replaced.

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