SYS.OK|MANUAL.DB● LIVE
HOMESERVICE MANUALSCHEVROLET2011MALIBU LTZ, 2.4 1REPAIR AND DIAGNOSISENGINE PERFORMANCEENGINE CONTROL SYSTEMSENGINE CONTROLS AND FUEL - 2.4L - REPAIR INSTRUCTIONSREPAIR INSTRUCTIONSFUEL LINE REPLACEMENT - CHASSISINSTALLATION PROCEDURE
2011 Chevrolet Malibu LTZ, 2.4 1

Installation Procedure

2011 Chevrolet Malibu LTZ, 2.4 1SECTION Installation Procedure
    Fig 1: Identifying Brake, Fuel & EVAP Pipe Retainers
    GM1797679Courtesy of GENERAL MOTORS CORP.
  1. Install and close the underbody retainers (5).
  2. Install and close the front of dash fuel feed/EVAP pipe retainers (4).
  3. Install and close the upper fuel feed/EVAP pipe retainer (3).
  4. Position the fuel feed/EVAP pipe assembly to the vehicle.
  5. Install the brake pipes to the retainers.
  6. Install the brake, fuel and EVAP pipe retainers (5) to the underbody studs.
    7. Fig 2: Identifying Fuel Tank & Chassis Fuel Feed Pipe
    GM1789402Courtesy of GENERAL MOTORS CORP.
  7. Remove the caps from the chassis fuel and EVAP pipes.
  8. Connect the fuel tank EVAP pipe quick connect fitting (2) to the chassis EVAP pipe (4). Refer to Plastic Collar Quick Connect Fitting Service .
  9. Connect the fuel tank fuel feed pipe quick connect fitting (1) to the chassis fuel feed pipe (3). Refer to Plastic Collar Quick Connect Fitting Service .
    10. Fig 3: Identifying Front Sub-Frame Mounting Bolts
    GM1580120Courtesy of GENERAL MOTORS CORP.
  10. Install the right rear frame reinforcement (3).
    11. CAUTION: Refer to Fastener Caution .
  11. Install the right rear frame bolts (4) and tighten to 100 N.m (74 lb ft) plus an additional 90 degrees using the J 45059  . See Special Tools .
  12. Lower the vehicle.
    13. Fig 4: Identifying Brake, Fuel & EVAP Pipe Clips
    GM1797674Courtesy of GENERAL MOTORS CORP.
  13. Install the brake pipes to the clips.
  14. Install the brake, fuel, and EVAP pipe clips (1, 2) to the studs on the front of dash.
    15. Fig 5: View Of Fuel Feed & EVAP Pipes
    GM1774990Courtesy of GENERAL MOTORS CORP.
  15. Remove the caps from the fuel rail pipe and the EVAP purge solenoid.
  16. Connect the EVAP line quick connect fitting (2) to the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service .
  17. Connect the fuel feed line quick connect fitting (3) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  18. Install the fuel feed line retainer (1) to the fuel line bracket.
  19. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
  20. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection (LE5, LE9, LY7) .
  21. Tighten the fuel fill cap.
  22. Inspect for leaks.
    1. Turn ON the ignition, with the engine OFF for 10 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

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.

Shop Manual-Ready ToolsFree Quote CheckQuote Shield Pro

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.