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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 >> Removal Procedure

Removal Procedure

    WARNING:

    Refer to Diesel/Gasoline Vapors Warning .

    WARNING:

    Refer to Safety Glasses Warning .

  1. Relieve the fuel system pressure. Fuel Pressure Relief 
  2. Drain the fuel tank. Fuel Tank Draining 
  3. Raise and support the vehicle. Lifting and Jacking the Vehicle .
  4. {If equipped} Underbody Rear Air Deflector-Right Side - Remove - Underbody Rear Air Deflector Replacement - Right Side (XFE)
  5. Exhaust Muffler - Remove - Exhaust Muffler Replacement (Dual Exhaust) , or Exhaust Muffler Replacement (Single Exhaust)
  6. Fig 1: Identifying Fuel Tank Hose/Pipes, EVAP Emission Canister And Wiring Harness Components
    GM4943216Courtesy of GENERAL MOTORS COMPANY

    Wiring Harness (1) - Disconnect [2x]

  7. Wiring Harness (1) @ Retainer (9) - Remove [5x]
  8. Fuel Tank Vent Pipe (2) @ Fuel Tank Filler Pipe (3) - Disconnect - Plastic Collar Quick Connect Fitting Service 
  9. Evaporative Emission Canister (4) @ Evaporative Emission Canister Filter Pipe (5) - Disconnect - Plastic Collar Quick Connect Fitting Service 
  10. Fuel Tank Filler Hose Clamp (6) - Remove
  11. Fuel Tank Filler Hose (7) @ Fuel Tank (8) - Remove
  12. GM4943218Courtesy of GENERAL MOTORS COMPANY

    Evaporative Emission Canister Purge Pipe (1) @ Evaporative Emission Pipe (2) - Disconnect - Plastic Collar Quick Connect Fitting Service 

  13. Fuel Feed Pipe (3) @ Fuel Feed Pipe (4) - Disconnect - Plastic Collar Quick Connect Fitting Service 
  14. GM4239878Courtesy of GENERAL MOTORS COMPANY

    Place a suitable adjustable jack under the fuel tank.

  15. Fuel Tank Strap Bolt (1) - Remove [4x]
  16. Fuel Tank Strap (2) - Remove [2x]
  17. GM4239886Courtesy of GENERAL MOTORS COMPANY

    Fuel Tank (1) - Remove

  18. If replacing fuel tank transfer parts as necessary.