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HOMESERVICE MANUALSCHEVROLET2005MALIBU LSREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 1 (ENGINE CONTROL SYSTEM - 2.2L (L61) - INTRODUCTION)REPAIR INSTRUCTIONSFUEL TANK 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: Capping Or Plugging Fuel Tank Feed And Vapor Return Pipes
    GM1236108Courtesy of GENERAL MOTORS CORP.
  1. If fuel tank replacement was necessary, install the fuel pump module assembly to the fuel tank. Refer to Fuel Sender Assembly Replacement (Malibu Sedan) .
  2. Have an assistant support the fuel tank during fuel tank and fuel tank strap installation.
  3. Begin to install the LH side of the fuel tank over the exhaust pipe.
  4. Raise the RH side of the fuel tank into position inboard of the RH frame rail. Use care in feeding the fuel feed, the EVAP vapor pipe, and the fuel pump module electrical harness over the exhaust system.
  5. Install the RH fuel tank strap and strap bolts.
  6. Install the LH fuel tank strap and strap bolts.
    7. NOTE: Refer to Fastener Notice in Cautions and Notices.
  7. Tighten the fuel tank strap bolts.

    Tighten:  Tighten the bolts to 20 N.m (15 lb ft).

    8. Fig 2: Releasing Exhaust Pipe Insulators From Underbody Hangers
    GM1238995Courtesy of GENERAL MOTORS CORP.
  8. Raise the exhaust into position and install the muffler insulator to the underbody hanger.
  9. Install the exhaust extension pipe insulators to the underbody hangers.
  10. Connect the fuel pump module harness electrical connector to the vehicle underbody connector.
    11. Fig 3: Fuel Filler Pipe Jumper Hose
    GM889977Courtesy of GENERAL MOTORS CORP.
  11. Connect the fuel filler pipe jumper hose to the fuel tank.
    12. NOTE: Refer to Component Fastener Tightening Notice in Cautions and Notices.
  12. Tighten the fuel filler pipe jumper hose clamp (1) at the fuel tank.

    Tighten:  Tighten the clamp to 4 N.m (35 lb in).

  13. Connect vapor recirculation line that runs parallel to the fuel filler pipe jumper hose.
  14. Remove the caps or plugs from the fuel tank feed and vapor return pipes.
  15. Connect the fuel feed and vapor purge lines to the fuel and brake line bundle on the right side of the vehicle.
  16. Connect the fuel sender electrical connector to the underbody harness and connect the EVAP purge valve electrical connector to the underbody harness.
  17. Attach the ABS harness (if applicable) to the retainer on the side of the EVAP canister.
  18. Lower the vehicle.
  19. Refill the fuel tank.
  20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  21. 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.
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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.