Chevy Malibu Gas Tank Removalby Gregory Crews
Lowering the gas tank on a Chevy Malibu is necessary in order to replace the gas tank, of course, but it's also required if you want to replace the fuel pump or repair the fuel gauge sending unit. The tank itself is not very heavy once you empty out the gasoline, but it is bulky. The tank is designed to hold up to 16 gallons of fuel plus a reserve of 2 gallons. You must remove two straps, fuel lines and a wiring harness on the Malibu before you can drop the gas tank.
Drain the fuel out of the gas tank. This will alleviate the weight of the tank when you are lowering it from the car. The fuel tank is located toward the back of the Malibu and sits just behind the rear wheels. Loosen the drain plug on the tank by turning it counterclockwise until the fuel starts draining. Then tighten the drain plug.
Securing the Car
Jack up the rear of the Chevy to give you more room to work. Jack up the car by the back tire or under the rear end. Ensure the parking brake is set and the wheels are chocked. This will help prevent accidental rolling. You can also use jack stands to secure the vehicle.
Locate the two straps underneath the vehicle, and loosen them with a socket wrench. There is a bolt on each side of the strap. Place a second jack underneath the center of the tank to ensure the tank is balanced. Lower the tank slowly once you have removed the straps; there are wires and hoses at the top to disconnect. Bring the tank down halfway. There is an inlet hose in the back of the tank that is held in place by a hose clamp. A flat-head screwdriver will loosen this clamp. Disconnect the wires at the top by separating them from the harness. Lift the tab on the wire connector and pull it away from the other connector. Disconnect the fuel lines the same way. Then lower the tank fully, and slide it out from underneath the Malibu.
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