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Home >> Chevrolet >> 2006 >> Malibu SS >> Repair and Diagnosis >> Engine Performance >> System >> Engine Control System - 3.9L - Introduction (2 Of 2) >> Repair Instructions >> Fuel Tank Replacement >> Installation Procedure
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Installation Procedure

Fig 1: View Of Fuel Tank Vapor Line
GM1580730Courtesy of GENERAL MOTORS CORP.
  1. If the fuel tank is being replaced, perform the following:
    Fig 2: Identifying Fuel Tank Electrical Harness
    GM1580732Courtesy of GENERAL MOTORS CORP.
  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.
    Fig 3: Identifying Fuel Tank Straps & Bolts
    GM1578463Courtesy of GENERAL MOTORS CORP.
  5. Completely raise and install the fuel tank into position.
    NOTE: Refer to FASTENER NOTICE .
    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.

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

  8. Remove the adjustable jack from under the fuel tank.
    Fig 4: Identifying Fuel Feed Line & Quick Connect Fittings
    GM1580724Courtesy of GENERAL MOTORS CORP.
  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 QUICK CONNECT FITTING(S) SERVICE (PLASTIC COLLAR) .
    Fig 5: Identifying Fuel Tank Jumper Electrical Connector
    GM1580942Courtesy of GENERAL MOTORS CORP.
  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.
    Fig 6: View Of Rear Antilock Brake System (ABS) Wiring Harness Connector
    GM1580941Courtesy of GENERAL MOTORS CORP.
  13. If applicable, engage the rear ABS wiring harness connector clip to the side of the EVAP canister bracket.
    Fig 7: Releasing Exhaust Pipe Insulators From Underbody Hangers
    GM1275979Courtesy of GENERAL MOTORS CORP.
  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.
    Fig 8: Identifying Clamp & Quick Connect Fittings
    GM1578466Courtesy of GENERAL MOTORS CORP.
  16. Connect the fuel fill pipe hose to the fuel tank.
  17. Tighten the fuel fill pipe hose clamp (1) at the fuel tank.

    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 QUICK CONNECT FITTING(S) SERVICE (PLASTIC COLLAR) .
  19. Connect the vapor recirculation line quick connect fitting (3). Refer to QUICK CONNECT FITTING(S) SERVICE (PLASTIC COLLAR) .
  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 DISCONNECT/CONNECT PROCEDURE .
  24. Inspect for fuel leaks using the following procedure:
    1. Turn ON the ignition, with the engine OFF for 2 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition, with the engine OFF.
    4. Inspect for fuel leaks.
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