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Home › Chevrolet › 2007 › Malibu SS › Repair and Diagnosis › Engine Performance › System › Engine Controls & Fuel - 3.9L - Introduction (2 Of 2) › Repair Instructions › Fuel Tank Module Replacement (Sedan) › Installation Procedure

Installation Procedure

CAUTION: Drain the fuel from the fuel sender assembly into an approved container in order to reduce the risk of fire and personal injury. Never store the fuel in an open container.
IMPORTANT:
  • Some lock rings were manufactured with "DO NOT REUSE" stamped into them. These lock rings may be reused if they are not damaged or warped.
  • Inspect the lock ring for damage due to improper removal or installation procedures. If damage is found, install a NEW fuel pump module.
  • Inspect the lock ring for flatness as best as possible. If the lock ring is warped, replace the fuel pump module.
    Fig 1: Fuel Pump Module
    GM1791658Courtesy of GENERAL MOTORS CORP.
  1. Clean any contamination from the male pipe ends of the fuel pump module.
  2. Place a NEW fuel tank module seal onto the fuel tank.
  3. Insert the fuel pump module into the fuel tank allowing the sensor arm and float to clear the module opening.
  4. Lower the module down into the fuel tank until the fuel tank vent pipe quick connect fitting can be connected.
    5. Fig 2: Fuel Tank Vent Pipe Quick Connect Fitting
    GM1790160Courtesy of GENERAL MOTORS CORP.
  5. Connect the fuel tank vent pipe quick connect fitting (1) at the module cover. Refer to Plastic Collar Quick Connect Fitting Service .
  6. Press the fuel tank module downward.
    7. Fig 3: View Of Fuel Tank
    GM1791653Courtesy of GENERAL MOTORS CORP.
  7. Reposition the EVAP emission canister vent line enough to install the J 45722 
  8. Install the J 45722  to the fuel pump module lock ring.
    9. Fig 4: Identifying Lock Ring
    GM1642096Courtesy of GENERAL MOTORS CORP.
    IMPORTANT: Ensure that the lock ring is installed with the correct side facing upward. A correctly installed lock ring will only turn in a clockwise direction.
  9. Using the J 45722  and a long breaker-bar, rotate the lock ring in a clockwise direction in order the lock the lock ring.
  10. Remove the J 45722  from the fuel pump module lock ring.
    11. Fig 5: Identifying Fuel Feed Pipe Retaining Features
    GM1790153Courtesy of GENERAL MOTORS CORP.
  11. Install the EVAP emission canister vent pipe to the retaining features (1) built into the fuel tank.
    12. Fig 6: Fuel Pump Module Wiring Harness Electrical Connectors
    GM1790125Courtesy of GENERAL MOTORS CORP.
  12. Connect the fuel tank fuel pump module wiring harness electrical connector (3) to the EVAP canister vent solenoid.
  13. Connect the fuel tank fuel pump module wiring harness electrical connectors (1, 2) to the fuel pressure sensor and the module.
  14. Install the fuel tank. Refer to Fuel Tank Replacement (Sedan)  or Fuel Tank Replacement (Maxx) .
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