Fuel pump wiring issue?

Tiny
ALEXARPI
  • MEMBER
  • 2004 CHEVROLET MALIBU
  • 3.6L
  • 6 CYL
  • 2WD
  • AUTOMATIC
  • 160,000 MILES
The fuel pump has been changed but the wiring harness that connects the fuel pump to the car wires got ripped apart where the wiring clips meet. We tried wiring them straight, but all the wires are giving lights on the dashboard. Also, the fuel pump sensor does not read on the dash. It shows empty. The wires in the bottom that where the female and male end of the harness, didn’t seem to match.
Thursday, September 1st, 2022 AT 1:15 PM

9 Replies

Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,885 POSTS
Hi,

The wires should all match except one. From the fuel level sensor, it will start as black with a white tracer. Where it connects, it will change to an orange wire with a black tracer. The remaining wires are as follows:

Gray = Power supply to pump from fuel pump relay.

Black = Ground located behind the right rear seat back.

Purple = Signal ground/low reference from the level sensor to PCM.

The fourth wire is the one that changes in color.

I attached a pic below referencing what I described.

Let me know if this helps or if you have other questions.

Take care,

Joe

See pic below.

Note: Because of the location of the wiring connector, it is important that when splicing them, make sure they are secure. They should be soldered, and heat shrank and then taped to prevent any type of short.
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Thursday, September 1st, 2022 AT 8:32 PM
Tiny
ALEXARPI
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There are 2 org/black wires that come from the car. One is a little bit thicker than the other.
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Friday, September 2nd, 2022 AT 9:34 AM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,885 POSTS
Hi,

According to the wiring schematic, there should only be one. Are both of these wires at the fuel pump wiring? Also, is it possible for you to take a pic and upload it for me to see?

Check to see if one or both of them have power when the key is first turned on. It will only get power for a couple of seconds and then stop until an ignition signal is received by the PCM.

Here is a link you may find helpful:

https://www.2carpros.com/articles/how-to-check-wiring

Let me know.

Joe
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Friday, September 2nd, 2022 AT 8:38 PM
Tiny
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These are the two wires that are the same. I have 5 dash lights on just from that one wire that got ripped Apart. How can I test them to see if the fuse went?
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Saturday, September 3rd, 2022 AT 3:36 PM
Tiny
ALEXARPI
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Here’s another pic.
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Saturday, September 3rd, 2022 AT 4:19 PM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,885 POSTS
Hi,

I see what you are referring to. I have a question. The one orange/black wire appears to have already been spliced together. On the one side, I see the black stripe. On the opposite side, I don't. Are you certain that it has a black stripe on it? See pic 1

As far as the fuse, it is located in the right rear of the trunk fuse box. When you check it, first confirm it is good. If it is, then confirm there is power to and from it.

Here is a link that explains how it's done:

https://www.2carpros.com/articles/how-to-check-a-car-fuse

It is fuse 25 and it will be a 15-amp fuse. (See pics 2 and 3)

Let me know what you find.

Joe

See pics below.
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Saturday, September 3rd, 2022 AT 10:55 PM
Tiny
ALEXARPI
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I found out that one of the orange wires that are unconnected is for the evap solenoid. What 2 colors connect for the evap solenoid so I can see which one is hot and ground?
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Wednesday, October 12th, 2022 AT 7:25 PM
Tiny
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And if the black wire for the fuel level sensor is that ground to make sure the cable, I connect is ground.
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Wednesday, October 12th, 2022 AT 7:32 PM
Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 109,885 POSTS
Hi,

The wiring from the fuel level sensor in the tank starts as one purple wire and one starts as black with a white tracer but changes to orange with a black tracer. The purple is the signal to the PCM, and the orange/black is the low reference. A low reference is a ground. It is different than a chassis ground because it is sourced from the PCM.

As far as the vent solenoid is concerned, the wires are white and red with a white tracer. The white wire is the control wire from the PCM. The red/white is power from fuse 5 (emissions 2). See pic 3, 4, and 5.

I hope this helps.

Take care,

Joe

See pics below.
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Thursday, October 13th, 2022 AT 6:24 PM

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