GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1997 🢒 Malibu 🢒 Engine 🢒 Engine Controls - 2.4L 🢒 Fuel Tank Replacement

Removal Procedure
  1. Remove the negative battery cable.

    2. Refer to

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

    in General Information.

  2. Drain the fuel tank. Refer to Fuel Tank Draining .
  3. Raise the vehicle and suitably support.

    4. Caution: Provide additional support when a vehicle is on a hoist in the following ways:

       • Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off.
       • Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off.
    Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.


    Object Number: 54520 Size: SH
  4. Remove the quick-connect fitting at the fuel filter.
  5. Grasp the nylon fuel line quick-connect fitting. Twist the quick-connect fitting 1/4 turn in each direction to loosen any dirt within fitting. Repeat for the other nylon fuel line quick-connect fitting.

    6. Caution: Wear safety glasses when using compressed air in order to prevent eye injury.

  6. Using compressed air, blow out dirt from the quick-connect fittings at end of the fuel lines.
  7. Remove the quick connect fittings at the end of the fuel lines. Refer to Servicing Quick Connect Fittings (Metal Collar) .
  8. Remove the muffler support bolts.
  9. Remove the exhaust rubber hangers. Allow exhaust system to rest on rear axle.
  10. Remove the hoses at tank from filler, vent and vapor pipes.

    11. Object Number: 49897 Size: SH
  11. With aid of an assistant, support fuel tank (1) and disconnect the two fuel tank retaining straps
  12. Lower the fuel tank.
  13. Remove the fuel tank pressure sensor electrical connector.
  14. Remove the fuel sender electrical connector.
  15. Remove the tank from the vehicle.
  16. Remove the sound insulators.
  17. Remove the fuel sender assembly from the tank. Refer to Fuel Sender Assembly Replacement .

Installation Procedure

    Object Number: 49897 Size: SH

    Important: Inspect all connectors for dirt and burrs. Clean or replace components/assemblies as required. Fuel line O-rings for cuts, nicks, swelling or distortion. Replace if necessary.

  1. Install the fuel sender assembly to tank. Refer to Fuel Sender Assembly Replacement .
  2. Install the sound insulators.
  3. With aid of an assistant, raise the fuel tank (1) to body.
  4. Install the fuel tank pressure sensor electrical connector.
  5. Install the fuel tank sender electrical connector.
  6. Install the fuel tank.
  7. Install the fuel tank retaining straps.

    8. Tighten
    Tighten the bolts to 35 N·m (26 lb ft)

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  8. Install the hoses to filler, vent and vapor pipes
  9. Install the exhaust rubber hangers.
  10. Install the muffler support bolts.

    11. Tighten
    Tighten the bolt to 15 N·m (11 lb ft).

    Caution: Always apply a few drops of clean engine oil to the male pipe ends before connecting the fuel pipe fittings in order to reduce the risk of fire and personal injury. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.

  11. Install the nylon fuel line and fuel filter quick-connect fittings.
    12. • Apply a few drops of clean engine oil to the male connector tube ends.
    • Push the connectors together to cause the retaining tabs/fingers to snap into place.
    • Once installed, pull on both ends of each connection to make sure they are secure.
  12. Lower the vehicle.
  13. Refill the tank.
  14. Install the negative battery cable.
  15. Inspect for fuel leaks through the following steps:
    16. 15.1. Turn the ignition switch to the ON position for 2 seconds
    15.2. Turn the ignition switch to the OFF position for 10 seconds.
    15.3. Turn the ignition switch to the ON position
    15.4. Check for fuel leaks.