GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Malibu 🢒 Engine 🢒 Engine Controls - 3.1L 🢒 Fuel Tank Filler Pipe Housing Replacement

Removal Procedure

    Object Number: 276548 Size: SH
  1. Open the fuel tank filler door.
  2. Remove the fuel tank filler cap from the filler neck.
  3. Remove the screws from the fuel tank filler pocket.
  4. Remove the fuel tank filler pocket (1) by disengaging the retaining lugs from the quarter panel.

Installation Procedure

    Object Number: 276548 Size: SH
  1. Install the fuel tank filler pocket (1) to the quarter panel.

    2. Push the fuel tank filler pocket (1) inward to engage the retaining lugs.

    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.

  2. Install the fuel tank filler pocket screws to the fuel tank filler pocket (1).

    3. Tighten
    Tighten the screws to 2 N·m (18 lb in).

  3. Install the fuel tank filler cap to the filler neck.
  4. Close the fuel tank filler door.