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Home >> Chevrolet >> 2017 >> Malibu LS >> Repair and Diagnosis >> Engine Performance >> Engine Control Systems >> Engine Controls And Fuel - 1.5L (LFV) - Repair Instructions >> Repair Instructions >> Fuel Pump Replacement >> Removal Procedure
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Removal Procedure

WARNING: Fuel/gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.
WARNING: Wear safety glasses in order to avoid eye damage.
CAUTION: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution .
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief 
  2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection (without KL9)Battery Negative Cable Disconnection and Connection (with KL9)
  3. Intake Manifold Cover - Remove Intake Manifold Cover Replacement
  4. Separate the charge air cooler outlet air tube from the throttle body and set aside. Refer to Charge Air Cooler Outlet Air Tube Replacement 
  5. Disconnect the fuel feed front pipe from the fuel pump. Refer to Fuel Feed Front Pipe Replacement 
  6. Remove and DISCARD the fuel feed intermediate pipe. Refer to Fuel Feed Intermediate Pipe Replacement 
  7. Disconnect the engine wiring harness electrical connectors (1) as necessary, including the electrical connector at the fuel pump.
    Fig 1: Engine Wiring Harness Electrical Connectors, Bracket And Bolts
    GM4860323Courtesy of GENERAL MOTORS COMPANY
  8. Remove the engine wiring harness bracket bolts (2) and reposition the engine wiring harness bracket (3).
  9. Remove the fuel pump insulator (1).
    Fig 2: Fuel Pump Insulator
    GM4860324Courtesy of GENERAL MOTORS COMPANY
    WARNING: The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise cancelling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage and possible injury or death.
  10. Remove and DISCARD the fuel pump bolts (1).
    Fig 3: Fuel Pump Bolts
    GM4860325Courtesy of GENERAL MOTORS COMPANY
    CAUTION: Alternately loosen the fuel pump bolts one turn at a time until the pump is fully disengaged from fuel pump lifter follower. Trying to remove the pump bolts without even side-to-side loosening may result in pump plunger damage
  11. Remove the fuel pump (2).
    NOTE: Ensure that during removal of the fuel pump that the valve lifter follower does NOT fall apart.
  12. Remove the valve lifter follower (3).
    NOTE:
    • The valve lifter follower MAY remain in the cylinder head bore after removing the fuel pump.
    • If the valve lifter follower does NOT pull out of the cylinder head bore with the fuel pump, then remove it afterwards.
  13. Remove and DISCARD the fuel pump housing seal (1).
    Fig 4: Fuel Pump Housing Seal
    GM4860326Courtesy of GENERAL MOTORS COMPANY
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