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Home › Chevrolet › 2010 › Malibu LS, 3.5 K › Repair and Diagnosis › Engine Performance › Engine Control Systems › Engine Controls And Fuel - 3.5L - Repair Instructions › Repair Instructions › Filler Tube Replacement › Installation Procedure

Installation Procedure

    Fig 1: Identifying Fuel Fill Pipe, EVAP Emission Pipe & Fuel Tank Vent Pipe
    GM1795261Courtesy of GENERAL MOTORS CORP.
  1. Install the fuel tank fill pipe.
  2. Install the fuel fill pipe hose to the fuel tank.
  3. Connect the fuel tank fill EVAP emission pipe quick connect fitting (2) to the fuel tank vent pipe (1). Refer to Plastic Collar Quick Connect Fitting Service .
    4. CAUTION: Refer to Fastener Caution .
  4. Tighten the fuel fill pipe hose clamp (3) at the fuel tank.

    Tighten:  Tighten the clamp to 4 N.m (35 lb in).

    5. Fig 2: Identifying Fuel Tank & Chassis Fuel Feed Pipe
    GM1789402Courtesy of GENERAL MOTORS CORP.
  5. Remove the caps from the fuel and EVAP pipes.
  6. Connect the fuel tank EVAP pipe quick connect fitting (2) to the chassis EVAP pipe (4). Refer to Plastic Collar Quick Connect Fitting Service .
  7. Connect the fuel tank fuel feed pipe quick connect fitting (1) to the chassis fuel feed pipe (3). Refer to Plastic Collar Quick Connect Fitting Service .
    8. Fig 3: Identifying Fuel Tank Fill Pipe & Bolts
    GM1837996Courtesy of GENERAL MOTORS CORP.
  8. Install the fuel tank fill pipe bolt (2) to the underbody side rail.

    Tighten:  Tighten the bolt to 9 N.m (80 lb in).

  9. Lower the vehicle.
  10. Install the fuel tank fill pipe bolts (1) to the fuel tank fill pipe housing.

    Tighten:  Tighten the bolt to 1.5 N.m (13 lb in).

  11. Refill the fuel tank.
  12. Tighten the fuel fill cap.
  13. Inspect for leaks.
    1. Turn ON the ignition, with the engine OFF for 10 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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