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.
Installation Procedure
2011 Chevrolet Malibu LTZ, 2.4 1SECTION Installation Procedure
- Have assistants support either side of the fuel tank.
- If applicable, begin to install the right side of the fuel tank over the muffler assembly.
- If applicable, raise the right side of the fuel tank into position inboard of the right frame rail. Use care in feeding the fuel feed, EVAP line wiring harness over the muffler assembly.
- If applicable and the muffler assembly was removed, have assistants raise the fuel tank into position.
- Install fuel tank straps and bolts and tighten the bolts to 20 N.m (15 lb ft).
- Raise the muffler assembly into position if applicable, otherwise install the muffler assembly. Refer to Exhaust Muffler Replacement (LE5 or LE9 With MH8) or Exhaust Muffler Replacement (LY7) .
- With the aid of an assistant, install the muffler insulators (1) to the underbody hangers.
- Remove the jackstand from under the muffler assembly.
- Install the fuel fill pipe hose to the fuel tank.
- Connect the fuel tank fill EVAP emission pipe quick connect fitting (2) to the fuel tank vent pipe (1). Refer to Plastic Collar Quick Connect Fitting Service .
- Tighten the fuel fill pipe hose clamp (3) at the fuel tank and tighten the clamp to 4 N.m (35 lb in).
- Remove the caps from the fuel and EVAP pipes.
- Connect the fuel tank EVAP pipe quick connect fitting (2) to the chassis EVAP pipe (4). Refer to Plastic Collar Quick Connect Fitting Service .
- 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 .
- Install the rear ABS wiring harness electrical connector (2) clip to the EVAP canister.
- Connect the body wiring harness electrical connector (1) to the rear ABS wiring harness electrical connector (2).
- Install the body wiring harness electrical connector clip (3) to the underbody.
- Connect the fuel pressure sensor connector if equipped.
- Connect the fuel tank fuel pump module wiring harness electrical connector (1) to the body wiring harness electrical connector (2).
- Lower the vehicle.
- Refill the fuel tank.
- Tighten the fuel fill cap.
- Inspect for leaks.
- Turn ON the ignition, with the engine OFF for 10 seconds.
- Turn OFF the ignition for 10 seconds.
- Turn ON the ignition, with the engine OFF.
- 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.
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.