How to Replace the Fuel Pump on a 2005 Chevrolet Malibuby Justin Cupler; Updated November 07, 2017
Items you will need
3 jack stands
Combination wrench set
Fuel siphon with a semi-rigid siphon hose
5-gallon fuel storage tanks (amount varies)
Thick shop cloths
130 mm lock ring tool (GM part No. J-45722)
Inch-pound torque wrench
The 2005 Chevrolet Malibu came standard with a 145-horsepower, 2.2-liter engine. This engine requires between 50 and 60 psi of fuel pressure to operate correctly. Without the correct fuel pressure your Malibu may experience decreased performance, rough idle, stumbling or may not even start at all. The fuel pump is what supplies the pressure to the entire system, so when it fails, you are bound to experience the aforementioned symptoms. Replacing the base level 2005 Malibu’s fuel pump is a tedious process, but the money you save doing it yourself is well worth it.
Fuel Tank Removal
Kick wheel chocks in front of the front tires. Lift the rear of the Malibu with a floor jack and slide jack stands under the rear suspension crossmember. Lower the vehicle onto the jack stands.
Find the fuel pump wiring harness on the upper, front part of the fuel tank. Unplug the wiring harness. Unscrew the gas cap from the vehicle to relieve the tank pressure. Start the Malibu’s engine and allow it to idle until it stalls. Crank the vehicle for an additional three seconds to relieve any residual pressure.
Connect a memory saver to the vehicle, using the memory saver’s instructions as your guide. Loosen the negative battery cable with a combination wrench and pull it from the battery. Set the cable aside to prevent inadvertent reconnection.
Insert a fuel siphon with a semi-rigid siphon hose into the fuel filler hose. Feed the siphon hose downward until you feel it contact the bottom of the fuel tank. Place the siphon’s drain hose into a 5-gallon fuel storage tank. Siphon the fuel from the tank, using the siphon’s pump. When the fuel storage container fills, release the vacuum from the siphon and transfer the drain hose to a new container, then restart this step.
Remove the siphon from the fuel filler hose once you cannot siphon any more fuel from the tank.
Crawl under the vehicle. Unplug the evaporative emissions vent valve solenoid’s wiring harness, which you can find on the rear, driver’s side of the fuel tank. If the vehicle has rear antilock brakes, pull the ABS wiring harness from the side of the evaporative emissions canister on the driver’s side of the fuel tank.
Move to the passenger’s side of the vehicle and find the fuel-and-brake line bundle. Squeeze the plastic ears on the quick connect fitting on each fuel pump line and pull each line away from the pump-to-engine lines. Wrap a thick shop cloth around the now open ends of the tank-to-engine fuel lines.
Loosen the hose clamp securing the rubber end of the fuel filler hose to the fuel tank, using a ratchet and socket. Pull the fuel filler hose from the tank with a slight twisting motion. Pull the vapor recirculation line -- the rubber hose that runs along the fuel filler hose – from its inlet on the fuel tank.
Position a jack stand under the muffler. Press all of the underbody rubber exhaust hangers from the exhaust system. Lower the exhaust until the muffler rests out of the fuel tank’s way, on the jack stand.
Instruct an assistant to hold upward pressure on the fuel tank to prevent it from falling. Remove the bolts securing the left side fuel tank straps, using a ratchet and socket, then the right side straps.
Lower the passenger’s side of the fuel tank first, with the aid of an assistant, to clear the exhaust system. Allow the tank to clear the passenger’s side frame rail, then move the tank toward the front, passenger’s side of the vehicle as you lower it from the vehicle. Pull the tank from under the vehicle.
Fuel Pump Removal
Unplug the wiring harness and disconnect the ventilation hose from the fuel pump.
Turn the fuel pump’s locking ring counterclockwise with a ratchet and 130 mm lock ring – GM part No. J-45722 – while your assistant holds the tank from spinning. Don’t be alarmed if the fuel pump module jumps upward slightly when you remove the ring, this is normal.
Lift the fuel pump module just enough to access the fuel tank ventilation connector on the underside of the fuel pump’s upper plate. Squeeze the ears on the quick disconnect fitting and unplug the ventilation connector. Remove the fuel pump assembly from the tank.
Pull the old O-ring off the fuel pump’s mounting hole on the tank, using a flat-head screwdriver.
Fuel Pump Installation
Install a new O-ring, which comes with the new pump, onto the fuel pump’s mounting hole in the tank.
Guide the fuel pump module into the tank and before completely seating it, connect the fuel tank’s ventilation hose to the underside of the pump’s upper plate. Press the ventilation tube upward until its quick-connect fitting snaps into place.
Lower the fuel pump module into the tank. Press downward on the fuel pump to until the modules upper panel is flush with the top of the tank. Sit the locking ring over the fuel pump, so its tabs align with the notches in the tank. Rotate the locking ring clockwise until it seats on its second stop – you will feel it click twice, the second click is its second stop.
Connect the wiring harness to the fuel pump and plug the ventilation hose to its outlet on top of the fuel pump.
Fuel Tank Installation
Slide the tank under the vehicle and with the aid of an assistant, lift the driver’s side of the tanks over the exhaust. Lift the passenger’s side of the tank upward, so it is just inside of the right side frame rail. Verify that you did not pinch the fuel pump wiring harness or fuel feed lines.
Instruct the assistant to hold the tank in place as you install the tank straps and hand-tighten their retaining bolts. Tighten the strap bolts to 15 foot-pounds, using a torque wrench and socket.
Tell your assistant to lift and hold the exhaust system, as you press the rubber hangers back onto their respective exhaust arms.
Connect the fuel pump’s main power wiring harness to the Malibu’s wiring harness
Press the fuel filler hose onto the inlet on the fuel tank and tighten its hose clamp to 35 inch-pounds, using an inch-pound torque wrench and socket. Press the vapor recirculation line into its inlet on the fuel tank.
Remove the shop cloths from the fuel pump-to-engine lines and press them into their respective fuel pump lines until you hear the quick connector snap into place.
Plug the evaporative emissions vent valve solenoid’s wiring harness tot eh Malibu’s wiring and press the ABS wiring harness back into place on the evaporative emissions canister, if applicable.
Raise the vehicle off the jack stands and remove the jack stands. Lower the Malibu to the ground. Reconnect the negative battery cable to the battery and tighten its retaining bolt to 13 foot-pounds.
Remove the memory saver. Tighten the gas cap until it clicks three times. Turn the ignition to the “Run” position for two seconds, then to the “Off” position for 10 seconds. Turn the ignition back to the “Run” position and check for fuel leaks from under the vehicle. Start the engine and verify that it idles normally. Shut the engine off.
Gasoline and its vapors are highly flammable. Keep all lit cigarettes and open flames away from your work area.