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Home › Chevrolet › 2004 › Malibu Base › Repair and Diagnosis › Engine Performance › System › Engine Control System (Introduction) - 2.2L (L61) › Repair Instructions › Fuel Sender Assembly Replacement (Malibu MAXX) › Installation Procedure

Installation Procedure

    Fig 1: Installing Fuel Sender Assembly (Malibu MAXX)
    GM1236114Courtesy of GENERAL MOTORS CORP.
  1. Install a new O-ring on the modular fuel sender to tank.
  2. Connect the ventilation harness inside the fuel tank to the bottom of the modular fuel sender cover.
  3. Align the cover "paddle" or anti-rotation feature with the corresponding feature in the top of the fuel tank.
  4. Slowly apply pressure to the top of the spring loaded sender cover until the sender aligns flush with the surface of the tank.
  5. Align the locking ring with the matching features on the fuel tank and install the J 45722  . See Special Tools and Equipment .
  6. Turn the lock ring until the ring seats on the second detent.
  7. Connect the electrical and ventilation connections to the modular fuel sender assembly cover.
  8. Install the fuel tank. Refer to Fuel Tank Replacement (Malibu Sedan)  and Fuel Tank Replacement (Malibu MAXX) .
  9. Lower the vehicle.
  10. Refill the tank.
  11. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  12. Inspect for fuel leaks through the following steps:
    1. Turn the ignition to the ON position for two seconds
    2. Turn the ignition to the OFF position for ten seconds.
    3. Turn the ignition to the ON position
    4. Check for fuel leaks.
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