Come along with Eric O at the SMA shop as he diagnoses and repairs this 2008 Chevy Malibu that has an engine light on with a P0463 Fuel Level Sensor Circuit High Voltage code and the customer also stated that the gas gauge does not work.
I've always been a GM guy. I am driving a Malibu now and I will be the first to come to your defence about the complaints about the stupid engineering. I just am amazed that these people are not ashamed to be in public. I gripe about them every time I have to work on my old car. So the aggravation at the engineers is justified.
You are the only one I know that uses a brass punch to remove the lock ring! So many people use screwdrivers and other metal tools that can spark! I was taught that years ago to us brass or wood. It gives me chills when I see people using tools that can spark and start a fire. Don't want to light that vapor up! Another great video man!
TY for this video. I braved this project on my 05 Malibu and was successful. Used floor jacks and stands on garage floor. Having a lift must be nice. Installing tank on my back with no helper was a bear. Paid about 30 bucks for the fuel level sender unit (Rock Auto) and found out from another source that this is a 1200 dollar job at some other shop. So I'm happy with the fix and thanks again Eric. BTW really enjoy your other videos. I keep learning tips and tricks.
You'd be a natural for large residential new construction plumbing; you are well versed in the theory, terminology, and install practices. Good job, Mr. O.
Well, I must confess, I didn't realize that you could just change out the level sensor on a fuel pump. Holy hell, I learned something today! Thanks Eric!
Mrs “0” is certainly a keeper! She is sooo easy going, I keep waiting for her to snap, but it never happens. I love her personality! Thanks for great videos!
Such a blessing to come home from a long day at the shop to an hour long SMA Video. And 2 Mrs. O Cameo's? Makes my day of fighting with a Nissan all better.
I run a small mobile mechanic service and I remember when I did a fuel pump replacement on a 05 Malibu. Worst job I've had by far. It was like 105 outside and the customer had a full tank of gas. At the time I had no means of emptying the fuel. Needles to say it took me 7 hours to change the pump and I almost passed out like 3 times from the heat and gas fumes.. just makes me feel a little more better now knowing it gave you a little bit of a struggle. Seeing as I had to do this with a foot and a half of clearance from the ground. And a heavy ass tank.. great video tho. I hope one day to get my own shop and lift! Makes everything 100 times faster.
Respect sir. At that point I would have been asking the customer how fast they would want to leave and if or if not they would mind a slightly large hole under there back seat lmao
Thank you!!! I am mechanically inclined but lack specific knowledge on fixes such as this. I just finished replacing the float in my wife's chevy Malibu thanks to you!!!!!!! If ever you are in Placerville, Ca I'll buy you a beer or 5
I've always been a fan of GM but the more I see the more I think my next vehicle will be...not a GM. Loved the commentary along the way. Your always entertaining. That system looks over complicated but whatever, it's what were up against these days. Thanks for having us in the shop! Nice closing.
What do I like most about Doctor Eric? He "never makes the same mistake twice, but makes all of them at least once" and when he does, he completely owns the mistake, apologizes and uses it as a teaching point to himself and all his viewers. The part in quotes is from a turn-of-the-century U.S. Cavalry field officers efficiency rating manual (a how to book) as an illustration of how to describe a new junior grade officer's job performance.
Thanks for walking us through the gas gauge sender replacement. What a freakin' job. Glad Dudes like you are around that can tackle/handle these septic tanks.
Just did this 2 days ago on a Malibu, so of course came across this video afterwards. It's like watching a movie for the second time and knowing where the next jump scare is :) Great video, it'll help those that manage to find it *before* the job a lot.
Eric you're the best I've ever seen!! My son took 2009 siverado to garage,changed fuel pump,still did'nt work.I watchedyou're video on fuel system sensor,plus broken wire. I bet one or other. I don't know why this shop did'nt do full scan before just changing fuel pump ?? I'm dieing to see if they charge for everything.Had truck 3days,still no answer. I'd like to show you're video. Thanks again Sonny
Used to drive old beaters from the 60's and 70's, and none of us had trouble with gas gauges not working, until they decided to put fuel pumps in the gas tanks. It used to be so easy, just two bolts and one threaded fuel line. I miss those days. This time, I cut out an access hole through the floor. It isn't always just a wire connection, though they can be difficult to get to sometimes.
Eric I sure wish you lived in Missouri I would definitely have you working on my car's it's so hard to find someone honest and actually knows what they're doing absolutely love watching your videos i get smarter every day thanks a lot
I'm not a GM guy, but I did have an 03 Buick, that was about the same body as the Malibu you're working on and it had a fuel gauge problem also. I have a friend who is all about Gm and when we talked about my gauge he told me most of them have an access panel in the trunk or under the rear seat. I pulled back the carpet in my truck and just up over the "Hump" in the truck was an access panel to get to the tank and take out the fuel pump. Just an FYI. It was my first and only and last Gm I'll ever own.
2008 chevy Malibu Classic Pump went in smoooooth after shaving tank and pump. It didn't even pop but is tight. Imperfect plastic tank molding left clinging plastic around pump hole. I shaved it off and slightly tapered the hole with a sharp knife. I wouldn't use a razor blade because it my slip and cut too much. Fuel pump had sharp edge on the lip where fits in, I shaved it rounded. After thet ZERO problems. I had to pull the tank twice in 3 days because the bad float sensor mimiked problem of a TSB where GM placed the vent hose (the one Eric had trouble with) too close to the float arm where it would rub and cause the gas guage to drop out ( $400 labor with a special $4.00 zip tie fix). I modified the opening because I didn't want the trouble I went through the first time like with Erics video. I used silicone grease on the pump gasket , lockring, and gasket seat on the tank. Alll went smooth after that. Video was invaluable. Nothing for this car on removing gas tank except for a "Aura?" . Had no problem with upper gas line disconnect by grabbing feedline back farther and using Eric's long 45 pliers. Video saved me mega time. Thanks.
I've gone thru these issues before especially with a rusty lock ring. Why does GM not put an access cover in the trunk for the fuel pump is beyond me. How much more could it cost? Fortunately my Grand Prix has one. That's why desperate GM owners & other DIYers decides to cut a hole in the trunk to make an access panel. Great video as usual, very detailed.
The sending unit from my $30 junkyard fuel pump assembly (pump damaged by puncturing the tank to drain it) didn't work. I disassembled it, bend-adjusted the "fingers," tested it, and it's been good so far for 2000+ miles. The fingers on the old unit were worn out. I carefully soldered on a couple tiny 3-strand wires & tested it. Now I have a spare. Also, as others have suggested, isn't there a trunk access panel for that Malibu's fuel pump assembly? My 2000 LeSabry has one. Another great video. I always learn from them.
Well Steve after watching this video I purchased a 2006 Saab 9-3 guess what? Same code and issue Tech2 shows 5v, but when I first drove it it was at half and suddenly while driving fell to Empty so I filled it up and now have a full tank and bad sending unit. Think I will drive it until around 350 miles then attempt the repair. SAAB WIS says that the repair is exactly what you did. Glad I have your video for inspiration. Car has 148,000 so I am going to replace the pump and all the complete assembly is 190.00 verses 49 for the sending unit.
Just did the same repair on my daughters Rav4. Toyota was very nice in providing a hatch for pump access behind the drivers seat... Hopefully GM will figure out that this works better than dropping the tank.
your videos have encouraged me to do what I want that makes me happy and start my own business, I favor more towards the diagnostic side of the automotive world.But nonetheless,I wanted to thank you. I went from a job that I absolutely despised, to doing what I love, thanks 💗
Maybe next time you go to the junkyard you should cut off the gas line opposset the quick disconnect to make a way to quickly connect a hose in the future.Love your show, keep up the good work.
best mechanic on youtube! i watch you all the time. as a mechanic myself i wish i can start my own shop someday and have my wife as my office manager too!
Your dogs are beautiful and well behaved. You know they ( car manufactures ) should make the engineers anything that they develop so as to make it a little easier on the mechanics down the road.
Another great video. Eric, get some safety glasses to keep that undercarriage crap out of your peepers. My mechanic Father used to hold both hands out, wiggle his fingers and say, only 10 to a customer, point to his eyes and say, only two of these to a customer. You are an inspiration to a lot of folks out here. Thank you.
A whole year and a half later.. I had to do this same exact job on my chevy Malibu.. ran into the same problems you did lol.. looking for insight and found your channel back then.. now today you do the job I was looking for on RU-vid lol.. awesome vid.. brings back nightmares of dropping my fuel tank on the ground with no lift 😂💪🏽💪🏽💪🏽
Mr and Mrs O.......You guys are like rock stars now.....63,000 peep's subed your channel..That makes us happy all of us. keep making and we'll keep watch'in.
so just a thought when I worked in a lumbermill as a oiler we would hock up a i/2 inch drill to the hand pump and use that to turn the pump, much easier on the arm, great video
I don't know why Eric but that "cheap little webcam quality" fits you. As soon as it cut to that scene I thought to myself...that is so Eric lol. Love the videos man I hope one day to have my own shop you are really inspiring me. Keep it up and thank you
Great info. I enjoy your videos because you do it in real time and don't pretend to be perfect. Keep up the good work. Like seeing Mrs. O also. Say hi.
Before any car company hires an automotive engineer, they must work 2 years at SMA with you. THEN and ONLY THEN do they get to go design cars. That way, they have their head out of their hoohaa. If you know what I mean.
Blaming an engineer for faulty designs is not that simple. They answer to greedy CEOs who want maximum profits and task the engineers with making a car cheaper every year and that often means quality and practicality gets tossed. Not to mention emissions control gets more and more stringent, which also plays a role. Always follow the money.
Blame the EPA. They write the book, specs, allowed fume leakage, natural engine off vacuum brings us to the in tank fuel pressure regulator, silver can at the bottom with one black wire is PTC thermistor for low fuel lamp, includes roll-over valve inside, that stops liquid fuel when too full to have room for expansion & contraction, plus venting fumes only to the canister instead of raw gas. Tank solenoid opens with no purge so fumes are captured in canister making an un-interrupted refueling event. And good job of checking codes and knowing they are set with key on but unplugged plus purge is aborted when fuel level is NOT between 80% full and 10% empty. It is all very elementary my dear Watson. DK, ASE master tech since 78, retired.
I too used to be a Chevy guy until I bought a 1986 Camaro in 1986 Had nothing but problems with it. Clutch pin constantly broke. Biggest problem was the car would hold the speed even if you took your foot off the gas. Ultra dangerous. Dealers did nothing to fix the problem and the factory didn't even acknowledge my complaint. I eventually sold the car to a used car dealer. A couple of years later, a friend had the same problem with their Camaro. They eventually found out it was the mass air censor. Pour hell for a $35 part. BTW: Just changed out the fuel pump in my 2001 Mazda Tribute. Took 20 min.
Sometimes on GM vehicles you can try a bottle of Techron in the tank and that may make the gauge work again. That will only work though if the resistor card is contaminated because of the sulfur content in the gas though. If the contacts are worn like these ones were, only a new sender will fix the problem.
I have always wanted to meet one of those GM engineers and ask them if they ever took replacing parts into consideration? Because there are so many parts that are close to impossible to replace and you need 7 knuckles to do it!!
They weren't dumb...They deliberately designed it so difficult so the day it needs to be serviced, the dealership can charge many hours of labour working on it !!!
I'm glad I have an 03 2500HD. I had to replace the fuel pump on it a few years ago. Rather than dropping the tank, I loosened the passenger side box halfway out, Then removed all the drivers side bolts out. I tilted the bad and had easy access to the pump.
Hi Eric yet another great video man. This would have been a great opportunity to show the variable resistor in you aeswave terminal kit showing the proof of wiring and fuel gauge. regards Joe
It makes me feel a lot better about fumbling around with my own vehicle when I see even you have to once in awhile like you did with the fuel pump coming out and going back in! lol
Great video, I used to love GM vehicles, but they have done so many irritating things, such as throwing the vehicle in low power mode, all the multiple service bulletins that many of should be recalls. I hate the electric power steering , especially when it goes out because of a weak battery, I Darn near crashed an o6 saturn ion over it. Speaking of the ion, they should have recalled the leaky defective fuel line on the thousands, who have had the problem. Thanks again for another great vid.
We need both Mrs. And Mr. O in texas, he would not know how to act not being able to deal with less rust on everything. I think up north even the plastic rust!!!!!
They always forever go bad when the tank is full. I remember the pump went bad on my conversion van. I had to drop the tank down in the driveway,I ended up drainging almost a full tank out of it. I only had a couple five gallon gas cans. I did have another vehicle in the yard so I ended up putting most of the gas in that vehicle. Still ended up with a couple gallons of gas in the tank. Why is it those gas tank gaskets are so much higher than the original. Had a hell of a time getting things to go back together.
I did a tank on a torrent i think it was. I had to remove two pieces to the sending unit they were connected inside the tank with a nylon tube and of course they put the release across the other side of the tank. Wow that was a joy.
That small filler neck vent line I usually take the bolt holding the filler neck out. You can move the neck around enough to make that pinch end able to be reached easily.
My wife's old Saturn is still in our driveway. Since at least 15yrs ago the gas gauge has worked intermittently, at best. With everything else that it needs, the sending unit is the least of its worries.
Great Video Eric your one of the best mechanics I have known...LOL...I heard you run down GM and I think they all have their drawbacks. Years ago I thought GM had the better car line but I believe they noticed Ford made a cheaper product so they started cheapening there's too. Its a shame but I guess it boils down to profits. I own a 2008 Impala and have really noticed the cheapness in quality.
open trunk, remove trunk mat, cut hole in trunk floor, remove pump. replace pump. put larger piece of sheet metal over hole, rivet in place. you're done.
I had a 98 Malibu that the gas gauge didn't work. I just remembered to fill er up every 300 miles like you do on a motorcycle (only every 100 miles on the bike)
Where's your helper Josh when you need him , leave Mrs. O alone she shouldn't be helping you remove a gas tank , that's why you have paid help @ your shop . Haven't you ever heard of a vacuum cleaner for the next time cleaning up all that dirt and dried up mud & salt on and around that gas tank . We still love watching your videos the cracks us up how you moan and complain especially about removing that fuel pump with that hose connection that was the best part .
Have you ever cleaned the contacts off of the fuel level sensor? I've done it a few times for friends that were tight on money. Only had one that messed up again a year or so later. If I remember right this was when you had to get the fuel pump module which was upwards of $400.00.
A friend was supposed to come over but it turns out he ran out of gas. I found out it was the fourth time. The mechanic wanted a lot of money to drop the fuel tank to fix the problem. He came over with a manual. I plugged the meter and found out the level sensor was fine, the gauge was bad. I wired in a new gauge and his problems were solved. 5 years later he told me the new gauge works perfectly. 1986 Oldsmobile Cutlass Siera. Fixed in 2013.
