Replacing The Fuel System In Your '06 Malibu

Replacing the fuel system in a 2006 Malibu is a moderately complicated job, best performed by a professional mechanic. The fuel pump is located inside the fuel tank, and can be accessed through an access panel in the passenger compartment or by removing the tank from the vehicle. Before beginning the replacement, it is important to disconnect the battery to reduce the risk of fire. The fuel tank will then need to be drained, and the fuel pump assembly removed. This may involve removing fuel lines, hoses, and electrical connections. Once the new fuel pump has been installed, the fuel tank can be reinstalled, and the fuel and electrical connections reconnected. Finally, the system should be tested for leaks and proper function.

Disconnect the battery and depressurise the fuel system

To disconnect the battery and depressurise the fuel system of a 2006 Malibu, follow these steps:

Disconnect the battery:

Use an 8mm wrench to disconnect the negative battery cable.

Depressurise the fuel system:

• With the car running, open the hood and access the fuse centre.
• Pull out the fuel pump relay. The car will stop running once it runs out of fuel.
• Alternatively, you can remove the gas cap to depressurise the system.
• If you need to completely depressurise the fuel system, you can open the drain valve at the bottom of the fuel tank and let the fuel run out.

Remove the fuel tank

To remove the fuel tank from a 2006 Malibu, first drain the fuel from the tank. This will make the tank much lighter when you are lowering it from the car. Loosen the drain plug on the tank by turning it counterclockwise until the fuel starts draining, then tighten it again. Jack up the rear of the car to give you more room to work. Ensure the parking brake is set and the wheels are chocked to prevent accidental rolling.

Next, locate the two straps underneath the vehicle and loosen them with a socket wrench. There is a bolt on each side of the strap. Place a second jack underneath the center of the tank to balance it. Now, slowly lower the tank. There are wires and hoses at the top to disconnect. Bring the tank down halfway. There is an inlet hose at the back of the tank that is held in place by a hose clamp. A flat-head screwdriver will loosen this clamp. Disconnect the wires at the top by lifting the tab on the wire connector and pulling it away from the other connector. Disconnect the fuel lines in the same way. Then, lower the tank fully and slide it out from underneath the Malibu.

Remove the fuel pump assembly

To remove the fuel pump assembly from a 2006 Malibu, you will need to first depressurise the fuel system. With the car running, open the hood and access the fuse centre. Pull out the fuel pump relay. After a while, your car will stop running because it will run out of fuel.

Next, disconnect the negative battery cable using an 8mm wrench.

Then, disconnect and remove the fuel tank. Spray the bolts on the straps holding the fuel tank with penetrating oil. Loosen the clamp at the top of the fuel neck. Remove the hose by twisting it free and pulling it off. Unplug the connectors by pulling out the safety tabs.

Make sure you have a catch pan ready, as this will leak fuel. Disconnect the rest of the hoses. Loosen the heat shield between the exhaust and the tank. Support the tank and remove the straps.

Now, you can remove the fuel pump assembly. Use needle-nose pliers to disconnect the locking tab at the top of the connector. Unplug the wiring from the fuel pump assembly. Use a chisel and hammer to remove the locking ring. Pull the fuel pump assembly up and out.

Finally, remove the old O-ring.

Install the new fuel pump

To install the new fuel pump, follow these steps:

Place the new O ring. Put the new assembly in and lock the locking ring in place by turning it clockwise into the brackets. Secure it with a hammer and chisel. Plug in the new lead and use wire taps to connect the wiring with the old square-ended lead. The new large black lead connects to the old black lead. The new thin black lead connects to the old black and white lead. The purple and purple leads connect as do the grey ones.

Jack the tank back up. Bolt the straps back in, tightening the bolts with a hand wrench. Reconnect all the harnesses. Reconnect the big tube. Reconnect all the fuel lines, remembering to remove the little green line protectors. Secure the heat shield. Reconnect the fuel neck.

Put the fuel pump relay back in. Reconnect the battery. Cycle the key a couple of times to make sure the fuel gauge is working. Start the car and check underneath for any fuel leaks.

Reinstall the fuel tank

Now that you've removed the old fuel pump and installed the new one, it's time to put the fuel tank back in place. Here's a step-by-step guide on how to do it:

Step 1: Jack the Tank Back Up

Use a jack to lift the fuel tank back into position. Make sure the tank is securely supported.

Step 2: Reattach the Straps

Bolt the straps that hold the fuel tank in place. Tighten the bolts with a hand wrench to secure the tank.

Step 3: Reconnect the Harnesses

Reconnect all the electrical harnesses and fuel lines that were previously disconnected. Make sure to remove any little green line protectors that may be on the new fuel lines before reconnecting them.

Step 4: Secure the Heat Shield

Secure the heat shield between the exhaust and the fuel tank. This will help protect the fuel tank from the heat of the exhaust.

Step 5: Reconnect the Fuel Neck

Reconnect the fuel neck, which is the tube that connects the fuel tank to the filler hose. Use a clamp to secure the connection and prevent leaks.

Step 6: Check the Fuel Gauge

Put the key in the ignition and cycle it a couple of times to ensure the fuel gauge is working properly. This will also prime the fuel pump.

Step 7: Reconnect the Battery

Reconnect the negative battery cable using an 8mm wrench.

Step 8: Start the Car and Check for Leaks

Start the car and carefully inspect the fuel tank and fuel lines for any signs of leaks. If there are no leaks, your new fuel pump installation is complete!

Remember to take all necessary safety precautions when working with fuel and electricity. It's also a good idea to have an assistant to help with the fuel tank installation process.

Frequently asked questions