Removal & Installation (Malibu) - 3.1L)

Disconnect the negative battery cable. Relieve the fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE . Drain the fuel tank.
Raise and support the vehicle. Disconnect the quick-connect fitting at the fuel filter. Disconnect the quick connect fittings at the end of the fuel lines. Remove the exhaust rubber hangers. Allow exhaust system to rest on rear axle. Remove the exhaust heat shield. Loosen the fuel tank filler hose clamp at the fuel tank.
Remove the hoses from the fuel tank filler, EVAP vent and EVAP vapor pipes. Disconnect the electrical harness from the multi-way rear body connector and fuel strap. With the aid of an assistant, support fuel tank and disconnect the two fuel tank retaining straps. Lower the fuel tank.
Disconnect the wiring harness from the modular fuel sender assembly and fuel tank pressure sensor. Disconnect the EVAP pipe and fuel pipe from the modular fuel sender and fill limiter vent valve.
Using Fuel Sender Lock Nut Tool (J-39765), press down and rotate the cam lock ring until free of the fuel sender retaining tabs. Remove the modular fuel sender assembly.
Install a NEW "O" ring on the fuel tank. Align the fuel lines parallel with the mark on the fuel tank. Slowly apply pressure to top of the spring loaded sender until the sender aligns flush with the retainer on the fuel tank. Install the cam lock ring using Fuel Sender Lock Nut Tool (J-39765). Be sure that the cam lock ring is fully seated within the tab slots.
To install the fuel tank, reverse removal procedure. Tighten fasteners to specification. See TORQUE SPECIFICATIONS . Lower the vehicle. Refill the fuel tank. Connect the negative battery cable.
Inspect for fuel leaks through the following steps. Turn the ignition switch to the ON position for two seconds. Turn the ignition switch to the OFF position for ten seconds. Turn the ignition switch to the ON position Check for fuel leaks.