Replacing The Fuel Pump In A 2003 Chevy Malibu

Replacing the fuel pump in a 2003 Chevy Malibu is a moderately complicated job. The fuel pump is located inside the fuel tank, and to access it, you will need to pull the tank. Before beginning the replacement, it is important to relieve the fuel system pressure and drain the fuel tank. You will also need to disconnect the negative battery terminal and various other components, such as the quick-connect fittings at the end of the fuel lines, the exhaust rubber hangers, and the electrical harness from the multi-way rear body connector. It is recommended to use a dealer part, OEM part, or a more expensive, higher-quality pump to ensure longevity. Additionally, you will need to replace the fuel filter if equipped.

Disconnect the negative battery terminal

Disconnecting the negative battery terminal is one of the first steps to take when changing the fuel pump in a 2003 Chevy Malibu. Here is a detailed, step-by-step guide on how to do this:

Step 1: Caution: Refer to the Battery Disconnect Caution in the Service Precautions. This is important for your safety and to ensure you don't cause any damage to the vehicle's electrical systems.

Step 2: Locate the negative battery terminal. The battery is typically located in the engine bay, on the side away from the engine. The negative terminal will be marked with a "-" symbol or a black cover.

Step 3: Before proceeding, ensure you have the necessary tools and safety equipment. You will need a wrench or socket that fits the battery terminal bolt. It is also recommended to wear protective gloves and eye protection.

Step 4: Loosen the nut or bolt that secures the negative battery cable to the terminal. You may need to hold the battery terminal still with one wrench or socket while loosening the nut/bolt with another. Be careful not to let the wrench or socket touch any other parts of the car, as this could cause an electrical short.

Step 5: Once the nut/bolt is loosened, carefully remove the cable from the battery terminal. Be aware that there may still be some residual power in the cable, so avoid touching any metal parts of the cable or allowing it to touch any metal parts of the car.

Step 6: If desired, you can now clean the battery terminal and cable with a wire brush to remove any corrosion. This will help ensure a good connection when you reconnect the battery.

Step 7: Insulate the negative battery cable to prevent accidental contact with the terminal. You can use electrical tape or a purpose-made battery terminal cover.

Step 8: Store the wrench or socket used for this task in a safe place, as you will need it again when you reconnect the battery.

It is important to note that disconnecting the battery will reset the vehicle's computer and cause the clock and radio presets to be lost. You may need to input a security code to reset the radio.

Drain the fuel tank

To drain the fuel tank of a 2003 Chevy Malibu, follow these steps:

Tools and Safety Precautions

• J 42960-2 fuel flapper door holder
• J42960-1 fuel drain hose
• Dry chemical (Class B) fire extinguisher
• Approved fuel storage container

Procedure

• Disconnect the negative battery terminal.
• Remove the fuel filler cap.
• Install the J 42960-2 fuel flapper door holder into the fuel fill pipe to hold the door open.
• Insert the J42960-1 fuel drain hose into the fuel tank until the hose reaches the bottom of the fuel tank.
• Use an air-operated pump device to drain as much fuel through the fuel fill pipe as possible.
• Refer to the Fuel Tank Draining Procedure in the service manual.
• Relieve the fuel system pressure.
• Raise the vehicle and support it securely. Refer to Lifting and Jacking the Vehicle in the General Information section of the service manual.
• Disconnect the quick-connect fitting at the fuel filter.
• Disconnect the quick-connect fittings at the end of the fuel lines.
• Remove the exhaust rubber hangers, allowing the exhaust system to rest on the rear axle.
• Remove the exhaust heat shield.
• Loosen the fuel tank filler hose clamp at the fuel tank.
• Remove the hoses from the fuel tank filler, EVAP vent, and EVAP vapor pipes.
• Disconnect the electrical harness from the multi-way rear body connector and fuel strap.
• With the aid of an assistant, support the fuel tank and disconnect the two fuel tank retaining straps.
• Lower the fuel tank.
• Disconnect the wiring harness from the modular fuel sender assembly and fuel tank pressure sensor.
• Disconnect the EVAP pipe and fuel pipe from the modular fuel sender and fill limited vent valve.

Once the fuel tank is drained and the above steps are completed, you can proceed to remove the fuel sender assembly from the tank and install the new fuel pump. Remember to always exercise caution when working with fuel and ensure proper ventilation in your work area.

Disconnect the quick-connect fitting at the fuel filter

To disconnect the quick-connect fitting at the fuel filter of your 2003 Chevy Malibu, you will need to first relieve the fuel system pressure and drain the fuel tank.

Next, raise the vehicle and support it securely. Refer to the Lifting and Jacking the Vehicle in General Information for guidance on this.

Now, disconnect the quick-connect fitting at the fuel filter. Then, disconnect the quick-connect fittings at the end of the fuel lines.

At this stage, you can remove the exhaust rubber hangers and allow the exhaust system to rest on the rear axle.

Following this, you can remove the exhaust heat shield and loosen the fuel tank filler hose clamp at the fuel tank.

Finally, remove the hoses from the fuel tank filler, EVAP vent, and EVAP vapor pipes.

Remove the fuel tank

To remove the fuel tank from a 2003 Chevy Malibu, first relieve the fuel system pressure and drain the fuel tank. Next, raise the vehicle and support it securely. Disconnect the quick-connect fitting at the fuel filter and the quick-connect fittings at the end of the fuel lines. Remove the exhaust rubber hangers and allow the exhaust system to rest on the rear axle. Remove the exhaust heat shield. Loosen the fuel tank filler hose clamp at the fuel tank and remove the hoses from the fuel tank filler, EVAP vent and EVAP vapor pipes. Disconnect the electrical harness from the multi-way rear body connector and fuel strap. With the aid of an assistant, support the fuel tank and disconnect the two fuel tank retaining straps. Finally, lower the fuel tank.

Disconnect the wiring harness from the modular fuel sender assembly

To disconnect the wiring harness from the modular fuel sender assembly, you will first need to relieve the fuel system pressure using a fuel pressure gauge. This is important to ensure that the fuel connections are safe for servicing. You will also need to drain the remaining fuel from the fuel pressure gauge into an approved container.

Next, raise the vehicle and support it securely. Refer to the Lifting and Jacking the Vehicle in General Information for guidance on this.

Disconnect the quick-connect fitting at the fuel filter and the quick-connect fittings at the end of the fuel lines. Remove the exhaust rubber hangers, allowing the exhaust system to rest on the rear axle.

Now, you can remove the exhaust heat shield and loosen the fuel tank filler hose clamp at the fuel tank. Remove the hoses from the fuel tank filler, EVAP vent, and EVAP vapor pipes.

With the aid of an assistant, support the fuel tank and disconnect the two fuel tank retaining straps. Lower the fuel tank.

At this point, you can disconnect the wiring harness from the modular fuel sender assembly and the fuel tank pressure sensor. Be careful, as the modular fuel sender assembly may spring up from its position when removing it from the fuel tank.

Frequently asked questions