Replacing The Fuel Float In Your 2004 Malibu: Step-By-Step Guide

If you're experiencing issues with your fuel gauge on your 2004 Malibu, it could be due to a faulty fuel pump sender/float/switch located inside the fuel tank. To fix this, you'll need to remove the fuel tank and either replace the sender or the entire fuel pump module. This is because the sender is part of the fuel pump assembly. You can expect to pay around $65 for the sender or $300 for the whole assembly. Alternatively, you can simply keep the tank full and continue driving until the pump fails completely.

Disconnect the battery and raise the car

To disconnect the battery and raise the car, follow these steps:

First, locate the battery. It is typically found in the engine bay, near the front of the car. Once you have located the battery, identify the negative terminal, which should be marked with a "-" symbol. Using a suitable wrench or socket, loosen the nut or bolt that secures the negative battery cable to the terminal. Be careful not to let the wrench or socket touch any metal parts of the car, as this could result in a short circuit. Once the nut or bolt is loose, carefully remove the cable from the terminal. If the cable is corroded or damaged, it may be necessary to clean or replace it before proceeding.

Next, you will need to raise the car safely. Place jack stands on a level surface and position them under the car, following the instructions in your car's manual. Ensure that the car is securely parked and the parking brake is engaged. Place wheel chocks or blocks behind the driving wheels to prevent accidental movement. Now, use a car jack to lift the car to a height that allows you to comfortably work underneath. Once the car is raised, securely engage the jack stands and remove the jack.

It is important to exercise caution when working underneath a raised car. Ensure that the car is securely supported by the jack stands and that you are not placing your body or any tools in a position where they could be trapped or injured if the car were to shift or fall. Keep children and pets away from the work area.

Now that the car is raised and the battery is disconnected, you can proceed with the next steps of changing the fuel float on your 2004 Malibu. Remember to consult a qualified mechanic or a detailed repair guide for specific instructions on replacing the fuel float.

Remove the fuel tank

To remove the fuel tank from a 2004 Malibu, you will first need to disconnect the battery and raise the car safely. You will then need to drain the fuel tank and disconnect the batter before you start.

Once the car is safely raised, you can begin to remove the fuel tank by first removing the straps that hold the tank in place. With the straps removed, carefully lower the tank, ensuring that you do not damage any other components. With the tank lowered, you can then remove the fuel pump module from the top of the tank. This will give you access to the fuel float, which can be replaced.

It is important to note that working on fuel systems can be dangerous, and proper safety precautions should always be followed. It is recommended to have a certified mechanic perform any repairs or maintenance on your vehicle's fuel system.

Remove the fuel pump module

To remove the fuel pump module, you will need to start by disconnecting the battery and raising the car safely. You will then need to drop the fuel tank. Once the tank is out, the fuel pump is held in place from the top of the tank with a lock ring. Remove the lock ring and take out the fuel pump module.

It is recommended that you replace the whole fuel pump module assembly, rather than just the sender, due to the high percentage failure rate on Chevy pumps.

When removing the fuel tank, you may want to refer to a guide on how to do so safely. You can also refer to a guide on how to remove the fuel pump module from the tank.

Please note that you will need to raise your car safely to complete this task.

Replace the fuel level sending unit

To replace the fuel level sending unit on a 2004 Malibu, you will need to remove the fuel tank. This is because the fuel level sending unit is part of the fuel pump assembly, which is located inside the fuel tank.

Start by disconnecting the battery and raising the car safely. You will then need to remove the fuel tank. Once the tank is out, the fuel pump is held in place from the top of the tank with a lock ring. Remove the lock ring and take out the old fuel pump assembly.

Get the new fuel pump assembly and install a new O-ring on the modular fuel sender. Connect the ventilation harness inside the fuel tank to the bottom of the modular fuel sender cover. Slowly apply pressure to the top of the spring-loaded sender cover until the sender aligns flush with the surface of the tank.

Finally, reinstall the fuel tank and reconnect the battery.

Reinstall the fuel tank

To reinstall the fuel tank of your 2004 Malibu, follow these steps:

Firstly, ensure the car is raised safely and securely, and the battery is disconnected. You will need to raise the car to gain access to the fuel tank, and for ease of reinstallation.

Next, carefully slide the fuel tank back into place, ensuring it is correctly aligned and positioned.

Reconnect the ventilation harness inside the fuel tank to the bottom of the modular fuel sender cover.

Now, slowly apply pressure to the top of the spring-loaded sender cover until the sender aligns flush with the surface of the tank.

Once the fuel tank is securely in place, you can reconnect the battery.

Finally, lower the car so it is no longer raised.

Your 2004 Malibu's fuel tank is now reinstalled.

Frequently asked questions