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HOMESERVICE MANUALSCHEVROLET2005MALIBU LSREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 1 (ENGINE CONTROL SYSTEM - 2.2L (L61) - INTRODUCTION)REPAIR INSTRUCTIONSFUEL SENDER ASSEMBLY REPLACEMENT (MALIBU SEDAN)INSTALLATION PROCEDURE
2005 Chevrolet Malibu LS

Installation Procedure

2005 Chevrolet Malibu LSSECTION Installation Procedure
WARNING: This page is about a different variant/trim than selected.
    Fig 1: Raising Fuel Sender Assembly Out Of Tank (Malibu Sedan)
    GM1236150Courtesy of GENERAL MOTORS CORP.
  1. Install a new O-ring on the modular fuel sender to tank.
  2. Connect the ventilation harness inside the fuel tank to the bottom of the modular fuel sender cover.
  3. Slowly apply pressure to the top of the spring loaded sender cover until the sender aligns flush with the surface of the tank.
  4. Align the locking ring with the matching features on the fuel tank and install the J 45722  . See Special Tools .
  5. Turn the lock ring until the ring seats on the second detent.
  6. Connect the electrical and ventilation connections to the modular fuel sender assembly cover.
  7. Install the fuel tank. Refer to Fuel Tank Replacement (Malibu Sedan) .
  8. Lower the vehicle.
  9. Refill the tank.
  10. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  11. Inspect for fuel leaks through the following steps:
    1. Turn the ignition to the ON position for two seconds
    2. Turn the ignition to the OFF position for ten seconds.
    3. Turn the ignition to the ON position
    4. Check for fuel leaks.
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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.