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HOMESERVICE MANUALSCHEVROLET2011MALIBU LTZ, 2.4 1REPAIR AND DIAGNOSISENGINE PERFORMANCEENGINE CONTROL SYSTEMSENGINE CONTROLS AND FUEL - 2.4L - REPAIR INSTRUCTIONSREPAIR INSTRUCTIONSFUEL TANK REPLACEMENTDISASSEMBLY PROCEDURE
2011 Chevrolet Malibu LTZ, 2.4 1

Disassembly Procedure

2011 Chevrolet Malibu LTZ, 2.4 1SECTION Disassembly Procedure
    Fig 1: Identifying Fuel Pump Module Wiring Harness Connectors
    GM1796271Courtesy of GENERAL MOTORS CORP.
  1. Disconnect the fuel tank fuel pump module wiring harness electrical connectors (1, 2) from the fuel pressure sensor, if equipped and the module.
    2. Fig 2: Identifying Fuel Pump Module Wiring Harness Connector
    GM1796263Courtesy of GENERAL MOTORS CORP.
  2. Disconnect the fuel tank fuel pump module wiring harness electrical connector (1) from the EVAP canister vent solenoid.
    3. Fig 3: Identifying Fuel Tank Vent Pipe Quick Connect Fittings
    GM1795288Courtesy of GENERAL MOTORS CORP.
  3. Disconnect the fuel tank vent pipe quick connect fitting (1) from the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
  4. Disconnect the fuel tank vent pipe quick connect fittings (3, 4) from the module. Refer to Plastic Collar Quick Connect Fitting Service .
    5. Fig 4: Identifying Fuel Tank Attachments
    GM1795283Courtesy of GENERAL MOTORS CORP.
  5. Remove the EVAP emission canister purge pipe from the retaining features (3) built into the fuel tank.
  6. Remove the fuel tank fuel pump module wiring harness from the retaining features (5) built into the fuel tank.
  7. Remove the fuel tank vent pipe from the retaining features (1) built into the fuel tank.
  8. Remove the fuel feed pipe from the retaining features (2, 4) built into the fuel tank.
    9. Fig 5: Identifying EVAP Canister Vent Solenoid & Retaining Bracket
    GM1796275Courtesy of GENERAL MOTORS CORP.
  9. Insert and gently push a small flat-bladed tool between the EVAP canister vent solenoid and the retaining bracket, disengaging the retaining tab (1).
    10. Fig 6: View Of EVAP Canister
    GM1796277Courtesy of GENERAL MOTORS CORP.
  10. Remove the EVAP canister bolt.
  11. Remove the fuel tank fuel pump module wiring harness from around the EVAP canister.
  12. Remove the EVAP canister and EVAP canister vent solenoid as an assembly.
    13. Fig 7: View Of Fuel Tank Fuel Pump Module Wiring Harness
    GM1796230Courtesy of GENERAL MOTORS CORP.
  13. Remove the fuel tank fuel pump module wiring harness.
    14. Fig 8: View Of Fuel Tank Vent Pipe
    GM1796282Courtesy of GENERAL MOTORS CORP.
  14. Remove the fuel tank vent pipe from the fuel tank.
    15. Fig 9: View Of Fuel Tank
    GM1796288Courtesy of GENERAL MOTORS CORP.
  15. Install the J 45722  to the fuel pump module lock ring. See Special Tools .
    16. Fig 10: Identifying Lock Ring
    GM1642096Courtesy of GENERAL MOTORS CORP.
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.