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HOMESERVICE MANUALSCHEVROLET2005MALIBU LSREPAIR AND DIAGNOSISENGINE PERFORMANCESYSTEMENGINE CONTROL SYSTEM - 3.5L (LX9) - INTRODUCTIONREPAIR INSTRUCTIONSFUEL HOSE/PIPES REPLACEMENT - CHASSISINSTALLATION PROCEDURE
2005 Chevrolet Malibu LS

Installation Procedure

2005 Chevrolet Malibu LSSECTION Installation Procedure
    Fig 1: View Of Fuel Hose/Pipe & Retainers At Vehicle Underbody
    GM49888Courtesy of GENERAL MOTORS CORP.
  1. Position the fuel feed pipe to the vehicle.
  2. With the rear of the pipe positioned slightly rearward and down, raise the front of the pipe into position.
  3. Install the remainder of the pipe into position.
  4. Install the fuel feed pipe to the pipe retainers.
  5. Secure the pipe retainers (1) to the vehicle underbody.
  6. Connect the fuel feed pipe and vapor return pipe to the lines at the fuel tank.
  7. Lower the vehicle.
    8. Fig 2: Identifying Pipe Retaining Clip
    GM879147Courtesy of GENERAL MOTORS CORP.
  8. Remove the caps or plugs from the fuel pipe and the engine fuel rail.
  9. Connect the fuel feed pipe to the engine fuel rail. Refer to Quick Connect Fitting(s) Service (Metal Collar) .
  10. Install the pipe retaining clip (1) to the fuel feed pipe.
  11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  12. Inspect for fuel leaks using the following procedure:
    1. Turn ON the ignition, with the engine OFF for 2 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition, with the engine OFF.
    4. Inspect for fuel leaks.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.