Chevrolet Malibu Gas Gauge Does Not Work

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.

[@mariofollowerofjesus8068]

Nice to see an honest mechanic who cares about his customers I also appreciate your channel being family friendly

[@sambitar8448]

DEAR SIR, YOU ARE #1 IN DIAGNOSTICS LOGIC WITH YOUR SIMPLYFIED OHMAGE OF FUEL LEVEL SENSOR. THANKS FOR YOUR CONTRIBUTION TO OUR AUTOMOTIVE FIELD.

[@Fireship1]

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!

[@davedennis6042]

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.

[@AceAuto-z8e]

Nice to see another husband and wife team in this industry. Your videos are helpful.

[@Raylude5]

The phone ringing off the hook and Mrs. O making her presence...all within the first minute....man this is going to be a good one 👍

[@jeremyhelton984]

Eric you have now saved me about $2000.00 in 2016 just buy watching your channel.I know you get this all of the time but seriously thank you!!!!

[@SouthMainAuto]

oh did I mention you can make the check payable to SMA... $1800 should do... hey you still saved $200!!

[@gino1948]

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.

[@atraxr603]

This is definitely my favorite car repair channel for sure. :D Thanks for taking the time to make these for us Eric. It's much appreciated.

[@Dustin_the_wind]

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.

[@emtscythe3782]

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.

[@baxrok2.]

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!

[@fordmodela3641]

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!

[@williamoneal2763]

They make a great couple and compliment each other. Great!

[@djjjamz]

Best repair channel on youtube. Keep it up eric.

[@ryanwilson8659]

He's definitely up there that's for sure.

[@crisprtalk6963]

no doubt.

[@grovercurry4469]

I'll)lolol)llll)lllll)ll)ll))lol I))l)lllll

[@joebazan1262]

Watching your videos have helped me diagnose my own vehicles thank you for sharing

[@peej123]

Mrs O must be taking lessons from my wife. Every time I need my wife to do something she is on the phone!!

[@jeremiemcknight8832]

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

[@wyattoneable]

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.

[@arthurbreeger8080]

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

[@spaceinvadertoo]

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.

[@robertdavis6708]

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.

[@lee11car80]

Great channel its refreshing to see a good mechanic at work

[@TrinsRealm]

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.

[@ryanwilson8659]

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

[@raybrensike42]

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.

[@gephrobodine]

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.

[@livefreeordietrying7242]

Im about TO DO THIS TO MY 06 MALIBU MAXX. I'M HAVING TO DO THIS ON THE FLOOR AS WELL. GAS LEAK ONLY THOUGH.

[@eddogg2eddogg25]

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

[@TheWicklunds25]

Eric you are one patient fella... I woulda been jumpin up and down on that tank tryin to get that o-ring to seat right.

[@stevesmith9932]

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.

[@63256325N]

Your gas recovery tank looks like the perfect candidate for a small electric motor....nice fix, well done. Thanks for the video.

[@dgxdetailingservicesltd8461]

Why when he can just use the vehicles pump like he did?

[@joatspremiumgarage2436]

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 💗

[@SouthMainAuto]

That's cool man! Get out there and get it done!

[@upallnight888]

Joats Premium A man that love what he do doesn't have to work a day.

[@aaronkuns]

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!

[@pontiacsrule8761]

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.

[@richfurber958]

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.

[@kevinrumsey1917]

Love your teachings. Ramsey Restorations. Shreveport, LA

[@robhunter2435]

Love the videos Eric. Keep them coming

[@wileycrutchfield6958]

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.

[@JHart-rd3nx]

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.

[@christrevena8138]

* well done Eric you are a genius I have no idea about mechanic work but you are really special at what you do

[@slantsix9783]

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.

[@quantumleap359]

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.

[@BigDaddy_MRI]

"Classic reach-around. And it would be lovely if it does". LOL... I love your commentary. Awesome.

[@danekeeper1]

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.

[@Doglover123-b8d]

"it's full and you need me?" "no, just saying, Good luck" that was priceless! lmbo

[@chungaleta1234]

Every vid is always better than the one before!!!

[@joecnc3341]

Another great video Eric O! Makes me NOT want to do this job myself.

[@Dirthauler65]

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.

[@ItsAlwaysRusty]

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.

[@SouthMainAuto]

Hahha GM figure it out!! That was a joke right?

[@sabergermd]

Another great video Eric O!

[@danmolumby4186]

Nicely done Eric. Long time subscriber.

[@scottsmith6571]

Great info and extreme detail .. you just don't throw stuff together an hope for the best . I see you are very thorough

[@Joshua.Muenchow]

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

[@SouthMainAuto]

Haha it's my welfare cam!

[@kyhomegarage3430]

Nice diagnoses and repair. Love your tap test. Keep up good work.

[@SouthMainAuto]

sometimes we just need to beat on it!

[@tonygriffiths2485]

Another one I have enjoyed. Having a ball here, catching up on the older ones as well. Superb Eirc Ty :)

[@georgegaspar233]

It must be tough to work overhead for hours on end. Kudos Eric.

[@alexandroalbares8765]

Beautiful diagnostic amigo

[@skokie23]

"The engineers at GM couldn't fix a sandwich" HAHAHAHAHHAAH That belongs on a T-Shirt!! :)

[@ddsr86]

I'd buy one

[@CoonMan]

i would buy 3 lol

[@yupsir791]

@@CoonMan sandwiches? Mmm now I'm hungry.

[@BigDaddy_MRI]

Me too.

[@exmember1607]

Why a t shirt? It’s not like the GM engineers could read it in the first place...

[@VolvoswedenSe]

Nice. A lot of new uploads in short time..Well done Eric..thumbs up

[@CHIBA280CRV]

Man that is a lot of work for a sensor. Thanks for sharing

[@averywellsand888]

I use to be a fan of GM but now I'm a fan of cheap and easy repairs and reliably

[@frankbath223]

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

[@AntonioClaudioMichael]

Wow that Fuel Sending Unit was very Porely made 😳 yikes what a pain Eric O freaking Chevy @SouthMainAutoRepairLLC

[@nomanjones4803]

My first car, a 1961 ford, I checked the gas level with a stick.

[@clarencek3658]

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 KZbin lol.. awesome vid.. brings back nightmares of dropping my fuel tank on the ground with no lift 😂💪🏽💪🏽💪🏽

[@SouthMainAuto]

Haha sorry you had to relive that!

[@joaquinjuarez6720]

You Sound Hideous.

[@robanderson84]

good job! i like how you teach but also learned with us about the resistance readings, keep being curious , i learn multiple things at each video

[@robertcowan8211]

BUDDY YOUR A BLESSED MAN. U N WIFE ARE A PERFECT MATCH. GOD BLESS U ALL...............WISH YOU WAS IN EAST, TN.

[@johnnybynum967]

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!!!!!

[@paulog8813]

I would love to see some work done to the old Jaguar on the side of the Malibu

[@bobvincent5921]

Let's see how the Brits car fares.

[@billscott7370]

Great job. I haven't seen a pump like that since my 1st job on a farm when I was in high school

[@rjb6327]

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.

[@rumbleseat262]

thanks for your time and for not being a tool along the way. Now lets see if I can apply what i've learned without losing my sh*t!

[@shaneharrison4775]

Cool I didn't know they made replacement float level indicators for the fuel pump modules awesome

[@dezblyan5125]

excellent video as usual eric

[@jesseruiz9292]

Definitely greatful thanks for the great video now I can go pull my Malibu tank down to see where it's leaking .

[@tectalabyss]

Hi Eric. I feel your pain Buddy I've been there. Has always Liked,Shared and added to my channels playlists. All my best. Bobby

[@EddieLeal]

13:42 "She's a squirter!" 🤣☔️

[@chadd.9119]

Working on my wife's 05 Malibu. I accidently broke the connector and kinked the line going from the evap canister going to the steel line going towards front of the car. It's about a foot long with the white connector.I know Dorman has a fuel line repair kit (Dorman 800-059), but it doesn't specify if it connects to steel or to plastic. I'm not sure if if they are different quick connects or not. Help!! lol Love your videos.....straight to the point without all the fluff.

[@LaPabst]

I'm a lifelong GM guy... couldn't agree more! I liked Disco too....

[@stephenmcgraw3610]

I know Eric never chat much i have a 2006 Malibu and the lady said the fuel gauge don't work this morning i decided to take the negative battery cable off and clean it real good And when I started the car the fuel gauge works now

[@klumpy103]

Interesting the stuff you find in these new fangled automobiles :-)

[@jimbola77]

excellent job partner thank you for sharing! people think car troubleshooting and fixin is easy!

[@2jimszrnorth802]

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.

[@Mytwistedvoices]

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.

[@BigDaddy_MRI]

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.

[@danieldoucet9121]

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.

[@seattleman3708]

I agree!!!

[@deankay4434]

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.

[@julianreid8179]

the hose in the groove sound good, bit could this be a factory thing or this could be the second pump?

[@henry3397]

Thanks for the great video, I watched mainly to see if you needed a new o-ring and I believe the answer is yes... but why would fuel ruin the o-ring? Isn't it made out of a fuel resistant material? Seeing as how its purpose is to seal any gas from escaping...

[@died4us590]

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.

[@arthurfricchione8119]

Eric dam good video. You show it like it is. Keep them coming. Nothing like the smell of raw fuel thanks

[@tiredoldmechanic1791]

A woman driving with a full tank of gas? Inconceivable!

[@tj37556]

She must be married lol

[@potatoesislife6365]

You keep using that word. I do not think it means what you think it means

[@damianface666]

That's using your head Eric great video keep them coming Thanks

[@wshultz74]

Great work! Enjoy watching.

[@ronjames9819]

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.

[@dalandser562]

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

[@anthonybarbee8828]

As always great job

[@davidhoekje7842]

When you were lowering that tank I was picturing the filler inlet right by your face and a nice splash of fuel sloshing out. Glad that didn't happen.

[@yvesdesrosiers2396]

Way to muscle it Hercul-O! Great Video as always. Thank You!

[@ericbrock9387]

In addition to your outdoor and SMA channels, you could start one devoted just to scanners!!

[@TorresMobileAutoRepair]

great video Eric!

[@lightningsmokerXx]

Wow , GM & Chrysler really keep Eric in business

[@dempseydixon5871]

Amazing Video, Just Think I Thought I Knew Something About Repairing Cars, But You Showed Me Something Completely New. Amazing Thanks

[@williamsquires3070]

(Around 24:50 or so) - looks at dogs, dogs look back like, “what you looking at me for? I’m not gonna hold up your muffler, I’m a dog, remember?” LOL! 🐶

[@whitsundaydreaming]

Did you check if you can access the pump from the trunk? This year may have the trap door over the pump.