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Home >> Chevrolet >> 2003 >> Malibu Base >> Repair and Diagnosis >> Engine Performance >> Remove, Overhaul & Install >> Engine Controls - Removal & Installation >> Fuel Systems >> Fuel Tank >> Installation
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Fuel Tank: Installation

  1. Install the fuel sender assembly to the fuel tank. See FUEL SENDER ASSEMBLY .
  2. Connect the 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 sensor.
  4. With the aid of an assistant, raise the fuel tank to the vehicle.
  5. Install the fuel tank retaining straps. Tighten the strap bolts to specification. See TORQUE SPECIFICATIONS .
  6. Connect the wiring harness into the multiway rear body connector.
  7. Connect the EVAP vapor pipe to the EVAP canister.
  8. Connect the fuel filler hose to the fuel tank. Tighten the fuel filler hose clamp to specification. See TORQUE SPECIFICATIONS .
  9. Install the rubber exhaust hangers.
  10. Install the exhaust heat shield. Tighten the exhaust shield bolt/nuts to specification. See TORQUE SPECIFICATIONS .
  11. Connect the fuel return pipe and fuel filter quick-connect fittings. See FUEL LINE DISCONNECT FITTINGS .
  12. Lower the vehicle.
  13. Refill the fuel tank.
  14. Install the fuel filler cap.
  15. Connect the negative battery cable. Tighten to specification. See TORQUE SPECIFICATIONS .
  16. Inspect for leaks by using the following procedure.
    • Turn ON the ignition for 2 seconds.
    • Turn OFF the ignition for 10 seconds.
    • Turn ON the ignition.
    • Inspect for fuel leaks.
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