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need install tips on how to install new fuel pump
Sent to Chevy Experts December 01 10:05 PM

Car will not start, had it towed to body shop, put on diagnostic machine, confirmed that car needs fuel pump. 2001 chevy malibu, 4 cyclinder. please help.

Customer (name blocked for privacy)
Status:  Closed   Value: $15
Answer
December 1 10:20 PM (15 minutes and 20 seconds later)
         
ACCEPTEDCheck Mark

You need to start by removing the fuel tank. The pump is connected to the sender unit on the bottom inside the tank. See below. Thanks

Document ID# 715168
2001 Chevrolet Malibu

Fuel Tank Replacement

Removal Procedure

  1. Drain the fuel tank.
  2. Relieve the fuel system pressure.
  3. Raise the vehicle and suitably support.
    Images available only to Customers.



  4. Disconnect the quick-connect fitting at the fuel filter.
  5. Disconnect the quick connect fittings at the end of the fuel lines.
  6. Remove the exhaust rubber hangers. Allow exhaust system to rest on rear axle.
  7. Remove the exhaust heat shield.
  8. Loosen the fuel tank filler hose clamp at the fuel tank.
  9. Disconnect the fuel tank filler hose from the fuel tank.
  10. Disconnect the EVAP vapor pipe from the EVAP canister.
  11. Disconnect the electrical harness from the multi-way rear body connector and fuel strap.
    Images available only to Customers.



  12. With the aid of an assistant, support fuel tank (1) and disconnect the two fuel tank retaining straps.
  13. Lower the fuel tank.
  14. Disconnect the wiring harness from the modular fuel sender assembly and fuel tank pressure sensor.
  15. Disconnect the evaporative emission (EVAP) pipe and fuel pipe from the modular fuel sender and fill limiter vent valve.
  16. Remove the fuel sender assembly from the tank.

Installation Procedure


    Images available only to Customers.



  1. Install the fuel sender assembly to tank.
  2. Connect the EVAP pipe to the modular fuel sender and fill limiter vent valve.
  3. Connect the wiring harness to the modular fuel sender assembly and fuel pressure sensor.
  4. With the aid of an assistant, raise the fuel tank (1) to the vehicle.

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  5. Install the fuel tank retaining straps.

    Tighten
    Tighten the bolts to 40 N·m (30 lb ft).

  6. Connect the wiring harness into the multi-way rear body connector.
  7. Connect the EVAP vapor pipe to the EVAP canister.
  8. Connect the fuel fill hose to the fuel tank.
  9. Tighten the filler hose clamp at the fuel tank.

    Tighten
    Tighten the filler hose clamp to 3 N·m (27 lb in)

  10. Install the exhaust rubber hangers.
  11. Install the exhaust heat shield.
  12. Connect the nylon fuel line and fuel filter quick-connect fittings.
  13. Lower the vehicle.
  14. Refill the tank and install the fuel fill cap.
  15. Connect the negative battery cable.
  16. Inspect for fuel leaks using the following procedure:
    1. Turn ON the ignition for 2 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition.
    4. Inspect for fuel leaks.

Document ID# 715168
2001 Chevrolet Malibu

Fuel Sender Assembly Replacement

Removal Procedure

Caution: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.


    Images available only to Customers.


Remove the fuel tank (4).

Important

  • The modular fuel sender assembly may spring up from position.
  • When removing the modular fuel sender assembly from the fuel tank, be aware that the reservoir bucket is full of fuel. The reservoir must be tipped slightly during removal to avoid damage to the float. Discard the fuel sender seal and replace the seal with a new one.
  • Carefully discard the reservoir fuel into an approved container.

 

  1. Press down and rotate the cam lock ring (1) until free of the fuel sender retaining tabs.
  2. Remove the modular fuel sender assembly.
  3. Remove the fuel level sensor.
Installation Procedure
  1. Install the fuel level sensor.
    Images available only to Customers.



  2. Install a new seal on the fuel tank (4).
  3. Align the fuel lines parallel with the mark on the fuel tank.
  4. Slowly apply pressure to top of the spring loaded sender until the sender aligns flush with the retainer on tank.

    Important

    Be sure that the cam lock ring is fully seated within the tab slots.

     

  5. Install the cam lock ring.
  6. Install the fuel tank (4).
Document ID# 715188
2001 Chevrolet Malibu


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