Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Removal Procedure
2005 Chevrolet Malibu LSSECTION Removal Procedure
WARNING: This page is about a different variant/trim than selected.
- Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
- Drain the fuel tank. Refer to Fuel Tank Draining Procedure .
- Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
- Disconnect the fuel pump module harness electrical connector from the vehicle underbody wiring harness.
- Disconnect the evaporative emissions (EVAP) vent valve solenoid harness electrical connector from the vehicle underbody wiring harness.
- If applicable, disengage the antilock brake system (ABS) wiring harness from the retainer on the side of the EVAP canister.
- Disconnect the fuel feed and purge lines at the fuel and brake line bundle on the right side of the vehicle.
- Cap or plug the fuel tank feed and vapor return pipes to prevent fuel loss and/or contamination.
- Loosen the fuel filler pipe jumper hose clamp at the fuel tank (1).
- Disconnect the fuel filler pipe jumper hose from the fuel tank.
- Disconnect the vapor recirculation line that runs parallel to the fuel filler pipe jumper hose.
- Release the exhaust pipe insulators from the underbody hangers.
- Release the muffler insulator from the underbody hanger and slowly lower the exhaust to rest on a tall jackstand. If this is not possible, remove the rear half of the exhaust system at the take down flange.
- Have an assistant support the fuel tank during fuel tank strap removal, and during tank removal. Or use an appropriate jack to support the fuel tank during removal
- Remove front LH fuel tank strap bolts.
- Remove the RH tank strap bolts.
- In order to clear the exhaust pipe, slowly lower the RH side of the fuel tank.
- Once the tank is clear of the RH frame rail, remove the fuel tank down and forward toward the RH side of the vehicle.
- If only the fuel tank is to be replaced, remove the fuel pump module assembly from the fuel tank. Refer to Fuel Sender Assembly Replacement (Malibu Sedan) .
RENDER: 1.0x
NO RELATED
Recommended Tools & Savings
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
Affiliate disclosure: We may earn a commission at no extra cost to you.
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.