The 2005 Chevrolet Malibu come standard through a 145-horsepower, 2.2-liter engine. This engine requires in between 50 and also 60 psi that fuel push to run correctly. There is no the exactly fuel press your Malibu might experience diminished performance, unstable idle, stumbling or might not also start in ~ all. The fuel pump is what offers the pressure to the entire system, so once it fails, you are bound to experience the abovementioned symptoms. Replacing the basic level 2005 Malibu’s fuel pump is a tedious process, yet the money you conserve doing it yourself is well worth it.

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Fuel Tank Removal

Kick wheel chocks in prior of the prior tires. Elevator the rear of the Malibu v a floor jack and also slide jack was standing under the behind suspension crossmember. Reduced the car onto the jack stands.

Find the fuel pump wiring exploit on the upper, front part of the fuel tank. Unplug the wiring harness. Unscrew the gas cap from the automobile to relax the tank pressure. Start the Malibu’s engine and permit it to idle till it stalls. Crank the automobile for an additional three seconds to relieve any kind of residual pressure.


Connect a memory saver come the vehicle, utilizing the storage saver’s instructions as your guide. Loosen the an adverse battery cable through a combination wrench and also pull the from the battery. Collection the cable beside to avoid inadvertent reconnection.

Insert a fuel siphon v a semi-rigid siphon hose into the fuel filler hose. Feed the siphon hose downward until you feel it call the bottom of the fuel tank. Place the siphon’s drainpipe hose right into a 5-gallon fuel warehouse tank. Siphon the fuel from the tank, utilizing the siphon’s pump. Once the fuel storage container fills, release the vacuum indigenous the siphon and transfer the drain hose come a new container, then restart this step.

Remove the siphon native the fuel filler hose as soon as you can not siphon any an ext fuel from the tank.

Crawl under the vehicle. Unplug the evaporative emissions vent valve solenoid’s wiring harness, which you can discover on the rear, driver’s next of the fuel tank. If the automobile has rear antilock brakes, pull the ABS wiring harness from the next of the evaporative emissions canister ~ above the driver’s side of the fuel tank.

Move come the passenger’s next of the vehicle and find the fuel-and-brake heat bundle. Squeeze out the plastic ear on the quick affix fitting on every fuel pump line and pull every line far from the pump-to-engine lines. Pave a thick shop cloth approximately the now open ends of the tank-to-engine fuel lines.

Loosen the hose clamp securing the rubber finish of the fuel filler water tap to the fuel tank, using a ratchet and socket. Traction the fuel filler water tap from the tank through a slight twisting motion. Pull the vapor recirculation line -- the rubber hose the runs follow me the fuel filler hose – indigenous its inlet ~ above the fuel tank.

Position a jack stand under the muffler. Press all of the underbody rubber exhaust hangers native the exhaust system. Lower the exhaust until the muffler rests the end of the fuel tank’s way, top top the jack stand.

Instruct an assistant to hold upward push on the fuel tank to avoid it native falling. Remove the bolts securing the left next fuel tank straps, utilizing a ratchet and socket, climate the right side straps.

Lower the passenger’s next of the fuel tank first, through the help of an assistant, to clear the exhaust system. Permit the tank to clean the passenger’s side framework rail, then relocate the tank towards the front, passenger’s next of the vehicle as you reduced it native the vehicle. Pull the tank native under the vehicle.

Fuel Pump Removal

Unplug the wiring harness and also disconnect the ventilation hose from the fuel pump.

Turn the fuel pump’s locking ring counterclockwise v a ratchet and also 130 mm lock ring – GM component No. J-45722 – while her assistant stop the tank from spinning. Nothing be alert if the fuel pump module jumps upward slightly as soon as you eliminate the ring, this is normal.

Lift the fuel pump module just sufficient to access the fuel tank ventilation connector on the underside the the fuel pump’s upper plate. Squeeze the ears on the fast disconnect fitting and also unplug the ventilation connector. Remove the fuel pump assembly indigenous the tank.

Pull the old O-ring off the fuel pump’s mounting feet on the tank, using a flat-head screwdriver.

Fuel Pump Installation

Install a new O-ring, which comes through the brand-new pump, top top the fuel pump’s mounting feet in the tank.

Guide the fuel pump module into the tank and also before fully seating it, attach the fuel tank’s ventilation hose to the underside of the pump’s top plate. Push the ventilation tube upward till its quick-connect fitting snaps right into place.

Lower the fuel pump module right into the tank. Push downward top top the fuel pump to till the modules upper panel is flush v the optimal of the tank. Sit the locking ring over the fuel pump, therefore its tabs align v the notches in the tank. Turn the locking ring clockwise till it seats on its second stop – you will feel the click twice, the 2nd click is its second stop.

Connect the wiring exploit to the fuel pump and also plug the ventilation water tap to the outlet on optimal of the fuel pump.

Fuel Tank Installation

Slide the tank under the vehicle and with the aid of an assistant, background the driver’s side of the tanks end the exhaust. Lift the passenger’s next of the tank upward, so the is just inside of the ideal side frame rail. Verify that you did not pinch the fuel pump wiring harness or fuel feeding lines.

Instruct the assistant to hold the tank in location as you download the tank straps and hand-tighten your retaining bolts. Tighten the strap bolts come 15 foot-pounds, using a speak wrench and also socket.

Tell her assistant come lift and also hold the exhaust system, together you push the rubber hangers ago onto their particular exhaust arms.

Connect the fuel pump’s key power wiring harness to the Malibu’s wiring harness

Press the fuel filler hose onto the inlet on the fuel tank and also tighten its water tap clamp come 35 inch-pounds, utilizing an inch-pound torque wrench and socket. Press the vapor recirculation line right into its inlet top top the fuel tank.

Remove the shop cloths from the fuel pump-to-engine lines and press them right into their respective fuel pump lines until you hear the quick connector snap right into place.

Plug the evaporative emissions vent valve solenoid’s wiring exploit tot eh Malibu’s wiring and press the ABS wiring harness back into place on the evaporative emissions canister, if applicable.

Raise the car off the jack stands and also remove the jack stands. Lower the Malibu to the ground. Reconnect the an adverse battery cable to the battery and also tighten that retaining bolt come 13 foot-pounds.

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Remove the memory saver. Tighten the gas cap until it clicks three times. Turn the ignition come the “Run” place for two seconds, climate to the “Off” position for 10 seconds. Rotate the ignition back to the “Run” position and check because that fuel leaks from under the vehicle. Begin the engine and also verify that it idles normally. Shut the engine off.