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Home >> Chevrolet >> 2025 >> Malibu LS >> Repair and Diagnosis >> Engine Performance >> System >> Engine Controls And Fuel - 1.5L - Repair Instructions >> Repair Instructions >> Fuel Tank Replacement >> Installation Procedure
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Installation Procedure

  1. GM4239886Courtesy of GENERAL MOTORS COMPANY

    Place a suitable adjustable jack under the fuel tank.

  2. Fuel Tank (1) - Install
  3. GM4239878Courtesy of GENERAL MOTORS COMPANY

    Fuel Tank Strap (2) - Install [2x]

    4. CAUTION:

    Refer to Fastener Caution .

  4. Fuel Tank Strap Bolt (1) - Install and tighten [4x] 27 N.m (20 lb ft)
  5. GM4943218Courtesy of GENERAL MOTORS COMPANY

    Fuel Feed Pipe (3) @ Fuel Feed Pipe (4) - Connect - Plastic Collar Quick Connect Fitting Service 

  6. Evaporative Emission Canister Purge Pipe (1) @ Evaporative Emission Pipe (2) - Connect - Plastic Collar Quick Connect Fitting Service 
  7. GM4943216Courtesy of GENERAL MOTORS COMPANY

    Fuel Tank Filler Hose (7) @ Fuel Tank (8) - Install

  8. Fuel Tank Filler Hose Clamp (6) - Install and tighten 4 N.m (35 lb in)
  9. Evaporative Emission Canister (4) @ Evaporative Emission Canister Filter Pipe (5) - Connect - Plastic Collar Quick Connect Fitting Service 
  10. Fuel Tank Vent Pipe (2) @ Fuel Tank Filler Pipe (3) - Connect - Plastic Collar Quick Connect Fitting Service 
  11. Wiring Harness (1) @ Retainer (9) - Install [5x]
  12. Wiring Harness (1) - Connect [2x]
  13. Exhaust Muffler - Install - Exhaust Muffler Replacement (Dual Exhaust) , or Exhaust Muffler Replacement (Single Exhaust)
  14. {If equipped} Underbody Rear Air Deflector-Right Side - Install - Underbody Rear Air Deflector Replacement - Right Side (XFE)
  15. Refill the fuel tank.
  16. Inspect for fuel leaks.
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