How To Replace A 2000 Chevy Malibu Fuel Pump

If you are having trouble with your Malibu stuttering or intermittent hesitation, you may not be getting enough fuel to the engine. This could be caused by a faulty fuel pump, which means that you may need to replace it. Follow these instructions to replace the fuel pump on your 2000 Chevrolet Malibu.

Removal

  1. Park on a flat, level surface. Disconnect negative battery cable.
  2. Drain all of the fuel out of the fuel tank into a gas can. Make sure that before you start that you have a gas can that can hold the amount of fuel in the tank or it will spill because once you start to siphon it you cannot stop it.
  3. The fuel system needs to be relieved of pressure.
  4. Jack the car up and make sure that it is secure on stands before you crawl under it.
  5. On the fuel filter, you need to disconnect the fitting. It is a quick-connect fitting.
  6. Take the exhaust hangers off and set the exhaust on the rear axle.
  7. Take the exhaust heat shield off.
  8. On the fuel tank, loosen the hose clamp for the fuel tank filler hose.
  9. Take the hoses to the fuel tank filler, EVAP vapor pipes and EVAP vent off.
  10. Undo the wiring harness from the fuel strap and the multi-way rear body connector.
  11. You now will disconnect the fuel tank straps and need to support the tank as you release it. You may need to get help with support of the tank as you lower it.
  12. Lower the tank.
  13. There is a wiring harness on the fuel tank pressure sensor and the modular fuel sender assembly. Disconnect this.
  14. Disconnect the fuel pipe and EVAP pipe from the fill limited vent valve and the modular fuel sender.
  15. Take the fuel sender assembly off the tank.

Installation

Before you replace the fuel pump, take the time to clean and inspect the connectors and o-rings. Look for dirt and any indication that the o-rings are damaged or going bad. Replace any worn parts before you go any further.

  1. Connect the fuel sender assembly to the tank.
  2. Reconnect the EVAP pipe and fuel pipe to the fill limited vent valve and modular fuel sender.
  3. Reconnect the electrical harness to the fuel pressure switch and modular fuel sender assembly.
  4. It may take two of you, but lift the tank back up and strap it back onto the body of the car.
  5. Tighten the bolts that hold the straps to 35 N.m (26 lb ft.)
  6. Reconnect the electrical harness to the multi-way rear body connector.
  7. Reconnect the hoses that go on the fuel tank filler, EVAP vapor pipes and EVAP vent.
  8. Make sure the filler hose clamp on the fuel tank is tightened.
  9. Reconnect the hoses that go to the filler, vapor pipes and vent.
  10. Reinstall the rubber hangers for the exhaust.
  11. Reconnect the quick-connect fittings to the fuel filter and fuel line.

You can now bring the car off the jack stands and refill the gas tank. Reconnect the battery and make sure that you have no gas leaks by turning it on and off. Turn the car ON for two seconds and OFF for 10 seconds. Turn the car back ON and look for leaks.

If you find that you are still getting a hesitation or stuttering when you are accelerating, you may have other problems within the fuel system. You should contact your local dealership if you run into any problems.