GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2006 🢒 Malibu 🢒 Engine 🢒 Engine Controls - 3.9L 🢒 Fuel Tank Replacement

Removal Procedure

    Object Number: 1578466 Size: SH
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.
  2. Drain the fuel tank. Refer to Fuel Tank Draining.
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
  4. Loosen the fuel fill pipe hose clamp (1) at the fuel tank.
  5. Disconnect and reposition the rear stabilizer shaft. Refer to Stabilizer Shaft Replacement.
  6. Disconnect the evaporative emission (EVAP) canister vent solenoid tube quick connect fitting (2). Refer to Plastic Collar Quick Connect Fitting Service.
  7. Disconnect the vapor recirculation line quick connect fitting (3). Refer to Plastic Collar Quick Connect Fitting Service.
  8. Disconnect the fuel fill pipe hose from the fuel tank.

    9. Object Number: 1275979 Size: SH
  9. Release the exhaust pipe insulators from the underbody hangers.
  10. 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.

    11. Object Number: 1580941 Size: SH
  11. If applicable, disengage the rear antilock brake system (ABS) wiring harness connector clip from the side of the EVAP canister bracket.

    12. Object Number: 1580942 Size: SH
  12. Disconnect the fuel tank jumper electrical connector from the underbody wiring harness.
  13. Disengage the underbody wiring harness connector clip from the EVAP canister bracket.

    14. Object Number: 1578463 Size: SH
  14. Use an appropriate adjustable jack to support the fuel tank during removal.
  15. Remove the fuel tank strap bolts.
  16. Remove the fuel tank straps.

    17. Object Number: 1580724 Size: SH
  17. Disconnect the fuel feed (2) and vapor (1) line quick connect fittings. Refer to Plastic Collar Quick Connect Fitting Service.
  18. Cap or plug the fuel feed and vapor lines in order to prevent fuel loss and/or system contamination.
  19. In order to clear the exhaust pipe, slowly lower the right side of the fuel tank.
  20. Once the tank is clear of the right frame rail, remove the fuel tank down and forward toward the right side of the vehicle.

    21. Object Number: 1580732 Size: SH
  21. If the fuel tank is being replaced, disconnect and remove the fuel tank electrical harness.

    22. Object Number: 1580730 Size: SH
  22. If the fuel tank is being replaced, perform the following:
    23. • Disconnect and remove the fuel tank vapor line. Refer to Plastic Collar Quick Connect Fitting Service.
    • Remove the EVAP canister. Refer to Evaporative Emission Canister Replacement.
    • Remove the EVAP canister vent solenoid valve. Refer to Evaporative Emission Canister Vent Solenoid Valve Replacement.
    • Remove the fuel sender. Refer to Fuel Tank Module Replacement.

Installation Procedure

    Object Number: 1580730 Size: SH
  1. If the fuel tank is being replaced, perform the following:
    2. • Install the fuel sender. Refer to Fuel Tank Module Replacement.
    • Install the EVAP canister vent solenoid valve. Refer to Evaporative Emission Canister Vent Solenoid Valve Replacement.
    • Install the he EVAP canister. Refer to Evaporative Emission Canister Replacement.
    • Install and connect the fuel tank vapor line. Refer to Plastic Collar Quick Connect Fitting Service.

    Object Number: 1580732 Size: SH
  2. If the fuel tank is being replaced, install and connect the fuel tank electrical harness.
  3. Begin to install the left side of the fuel tank over the exhaust pipe.
  4. Raise the right side of the fuel tank into position inboard of the right frame rail. Use care in feeding the fuel feed, EVAP vapor line, and the fuel sender electrical harness over the exhaust system.

    5. Object Number: 1578463 Size: SH
  5. Completely raise and install the fuel tank into position.

    6. Notice: Refer to Fastener Notice in the Preface section.

    Important: Ensure that the strap marked with the "L" is installed on the left side and the strap marked "R" is installed on the right side.

  6. Install the fuel tank straps.
  7. Install the fuel tank strap bolts.

    8. Tighten
    Tighten the bolts to 20 N·m (15 lb ft).

  8. Remove the adjustable jack from under the fuel tank.

    9. Object Number: 1580724 Size: SH
  9. Remove the caps or plugs from the fuel feed and vapor lines.
  10. Connect the fuel feed (2) and vapor (1) line quick connect fittings. Refer to Plastic Collar Quick Connect Fitting Service.

    11. Object Number: 1580942 Size: SH
  11. Connect the fuel tank jumper electrical connector to the underbody wiring harness.
  12. Engage the underbody wiring harness connector clip to the EVAP canister bracket.

    13. Object Number: 1580941 Size: SH
  13. If applicable, engage the rear ABS wiring harness connector clip to the side of the EVAP canister bracket.

    14. Object Number: 1275979 Size: SH
  14. Raise the exhaust into position and install the muffler insulator to the underbody hanger.
  15. Install the exhaust extension pipe insulators to the underbody hangers.

    16. Object Number: 1578466 Size: SH
  16. Connect the fuel fill pipe hose to the fuel tank.
  17. Tighten the fuel fill pipe hose clamp (1) at the fuel tank.

    18. Tighten
    Tighten the clamp to 4 N·m (35 lb in).

  18. Connect the EVAP canister vent solenoid tube quick connect fitting (2). Refer to Plastic Collar Quick Connect Fitting Service.
  19. Connect the vapor recirculation line quick connect fitting (3). Refer to Plastic Collar Quick Connect Fitting Service.
  20. Position and connect the rear stabilizer shaft. Refer to Stabilizer Shaft Replacement.
  21. Lower the vehicle.
  22. Refill the fuel tank.
  23. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
  24. Inspect for fuel leaks using the following procedure:
    25. 24.1. Turn ON the ignition, with the engine OFF for 2 seconds.
    24.2. Turn OFF the ignition for 10 seconds.
    24.3. Turn ON the ignition, with the engine OFF.
    24.4. Inspect for fuel leaks.