GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 Malibu 🢒 Engine 🢒 Engine Controls and Fuel - 3.5L 🢒 Fuel Hose/Pipes Replacement - Chassis

Removal Procedure

    Object Number: 1774990 Size: SH
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  2. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
  3. Remove the fuel feed and evaporative emission (EVAP) clip (1) from the manifold absolute pressure (MAP) sensor bracket.
  4. Disconnect the fuel feed pipe quick connect fitting (3) from the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  5. Disconnect the EVAP pipe quick connect fitting (2) from the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service .
  6. Cap the fuel rail pipe and the EVAP purge solenoid in order to prevent possible fuel and/or EVAP system contamination.

    7. Object Number: 1797674 Size: SH
  7. Remove the brake, fuel, and EVAP pipe clips (1, 2) from the studs on the front of dash.
  8. Remove the brake pipes from the clips.
  9. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

    10. Object Number: 1789402 Size: SH
  10. Disconnect the fuel tank fuel feed pipe quick connect fitting (1) from the chassis fuel feed pipe (3). Refer to Plastic Collar Quick Connect Fitting Service .
  11. Disconnect the fuel tank EVAP pipe quick connect fitting (2) from the chassis EVAP pipe (4). Refer to Plastic Collar Quick Connect Fitting Service .
  12. Cap the chassis fuel and EVAP pipes in order the prevent possible fuel and/or EVAP system contamination.

    13. Object Number: 1797679 Size: SH
  13. Remove the brake, fuel and EVAP pipe retainers (5) from the underbody studs.
  14. Remove the brake pipes from the retainers.
  15. Remove the fuel feed/EVAP pipe assembly from the vehicle.
  16. Place the pipe assembly on a work bench.
  17. Open and remove the upper fuel feed/EVAP pipe retainer (3).
  18. Open and remove the front of dash fuel feed/EVAP pipe retainers (4).
  19. Open and remove the underbody retainers (5).
  20. Replace any retainers as necessary.

Installation Procedure

    Object Number: 1797679 Size: SH
  1. Install and close the underbody retainers (5).
  2. Install and close the front of dash fuel feed/EVAP pipe retainers (4).
  3. Install and close the upper fuel feed/EVAP pipe retainer (3).
  4. Position the fuel feed/EVAP pipe assembly to the vehicle.
  5. Install the brake pipes to the retainers.
  6. Install the brake, fuel and EVAP pipe retainers (5) to the underbody studs.

    7. Object Number: 1789402 Size: SH
  7. Remove the caps from the chassis fuel and EVAP pipes.
  8. Connect the fuel tank EVAP pipe quick connect fitting (2) to the chassis EVAP pipe (4). Refer to Plastic Collar Quick Connect Fitting Service .
  9. Connect the fuel tank fuel feed pipe quick connect fitting (1) to the chassis fuel feed pipe (3). Refer to Plastic Collar Quick Connect Fitting Service .
  10. Lower the vehicle.

    11. Object Number: 1797674 Size: SH
  11. Install the brake pipes to the clips.
  12. Install the brake, fuel, and EVAP pipe clips (1, 2) to the studs on the front of dash.

    13. Object Number: 1774990 Size: SH
  13. Remove the caps from the fuel rail pipe and the EVAP purge solenoid.
  14. Connect the EVAP pipe quick connect fitting (2) to the EVAP purge solenoid. Refer to Plastic Collar Quick Connect Fitting Service .
  15. Connect the fuel feed pipe quick connect fitting (3) to the fuel rail. Refer to Metal Collar Quick Connect Fitting Service .
  16. Install the fuel feed and EVAP pipe clip (1) to the MAP sensor bracket.
  17. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement .
  18. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  19. Tighten the fuel fill cap.
  20. Inspect for leaks.
    21. 20.1. Turn ON the ignition, with the engine OFF for 10 seconds.
    20.2. Turn OFF the ignition for 10 seconds.
    20.3. Turn ON the ignition, with the engine OFF.
    20.4. Inspect for fuel leaks.