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Home >> Chevrolet >> 2005 >> Malibu Maxx >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 1 (Engine Control System - 2.2L (L61) - Introduction) >> Repair Instructions >> Fuel Tank Replacement (Malibu Sedan) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure .
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  4. Disconnect the fuel pump module harness electrical connector from the vehicle underbody wiring harness.
  5. Disconnect the evaporative emissions (EVAP) vent valve solenoid harness electrical connector from the vehicle underbody wiring harness.
  6. If applicable, disengage the antilock brake system (ABS) wiring harness from the retainer on the side of the EVAP canister.
  7. Disconnect the fuel feed and purge lines at the fuel and brake line bundle on the right side of the vehicle.
    8. Fig 1: Capping Or Plugging Fuel Tank Feed And Vapor Return Pipes
    GM1236108Courtesy of GENERAL MOTORS CORP.
  8. Cap or plug the fuel tank feed and vapor return pipes to prevent fuel loss and/or contamination.
    9. Fig 2: Fuel Filler Pipe Jumper Hose
    GM889977Courtesy of GENERAL MOTORS CORP.
  9. Loosen the fuel filler pipe jumper hose clamp at the fuel tank (1).
  10. Disconnect the fuel filler pipe jumper hose from the fuel tank.
  11. Disconnect the vapor recirculation line that runs parallel to the fuel filler pipe jumper hose.
    12. Fig 3: Releasing Exhaust Pipe Insulators From Underbody Hangers
    GM1238995Courtesy of GENERAL MOTORS CORP.
  12. Release the exhaust pipe insulators from the underbody hangers.
  13. 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.
    14. Fig 4: Capping Or Plugging Fuel Tank Feed And Vapor Return Pipes
    GM1236108Courtesy of GENERAL MOTORS CORP.
  14. 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
  15. Remove front LH fuel tank strap bolts.
  16. Remove the RH tank strap bolts.
  17. In order to clear the exhaust pipe, slowly lower the RH side of the fuel tank.
  18. Once the tank is clear of the RH frame rail, remove the fuel tank down and forward toward the RH side of the vehicle.
  19. 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) .
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