GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2000 🢒 Malibu 🢒 Preface 🢒 Cautions and Notices 🢒 Fuel Tank Replacement

Removal Procedure
  1. Drain the fuel tank. Refer to Fuel Tank Draining .
  2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  3. Raise the vehicle and suitably support. Refer to Lifting and Jacking the Vehicle in General Information.

    4. Object Number: 54520 Size: SH
  4. Disconnect the quick-connect fitting at the fuel filter. Refer to Plastic Collar Quick Connect Fitting Service .
  5. Disconnect the quick connect fittings at the end of the fuel lines. Refer to Metal Collar Quick Connect Fitting Service .
  6. Remove the exhaust rubber hangers. Allow exhaust system to rest on rear axle.
  7. Remove the exhaust heat shield.
  8. Loosen the fuel tank filler hose clamp at the fuel tank.
  9. Remove the hoses from the fuel tank filler, EVAP vent and EVAP vapor pipes.
  10. Disconnect the electrical harness from the multi-way rear body connector and fuel strap.

    11. Object Number: 49897 Size: SH
  11. With the aid of an assistant, support fuel tank (1) and disconnect the two fuel tank retaining straps.
  12. Lower the fuel tank.
  13. Disconnect the wiring harness from the modular fuel sender assembly and fuel tank pressure sensor.
  14. Disconnect the EVAP pipe and fuel pipe from the modular fuel sender and fill limiter vent valve.
  15. 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. Connect the fuel pipe and EVAP pipe to the modular fuel sender and fill limiter vent valve.
  3. Connect the wiring harness to the modular fuel sender assembly and fuel pressure switch.
  4. With the aid of an assistant, raise the fuel tank (1) to the vehicle.

    5. 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.

  5. Install the fuel tank retaining straps.

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

  6. Connect the wiring harness into the multi-way rear body connector.
  7. Connect the hoses to the fuel tank filler, EVAP vent and EVAP vapor pipes.
  8. Tighten the filler hose clamp at the fuel tank.
  9. Connect the hoses to filler, vent and vapor pipes
  10. Install the exhaust rubber hangers.
  11. Connect the nylon fuel line and fuel filter quick-connect fittings. Refer to Plastic Collar Quick Connect Fitting Service .
  12. Lower the vehicle.
  13. Refill the tank and install the fuel fill cap.
  14. Connect the negative battery cable. Refer to Battery Replacement in Engine Electrical.
  15. Inspect for fuel leaks using the following procedure:
    16. 15.1. Turn ON the ignition, for 2 seconds
    15.2. Turn OFF the ignition, for 10 seconds.
    15.3. Turn ON the ignition.
    15.4. Inspect for fuel leaks.