GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 Malibu Classic 🢒 Engine 🢒 Engine Controls and Fuel - 3.5L 🢒 Filler Tube Replacement

Filler Tube Replacement Sedan

Removal Procedure

Important: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order the avoid possible system contamination.


    Object Number: 1791673 Size: SH
  1. Remove the fuel fill cap.
  2. Drain the fuel tank. Refer to Fuel Tank Draining.
  3. Remove the fuel tank fill pipe bolt (1) from the fuel tank fill pipe housing.
  4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
  5. Remove the fuel tank fill pipe bolt (2) from the underbody side rail.

    6. Object Number: 1789402 Size: SH
  6. Disconnect the fuel tank fuel feed pipe quick connect fitting (1) from the chassis fuel feed pipe (3). Refer to Plastic Collar Quick Connect Fitting Service.
  7. Disconnect the fuel tank EVAP pipe quick connect fitting (2) from the chassis EVAP pipe (4). Refer to Plastic Collar Quick Connect Fitting Service.
  8. Cap the chassis fuel and EVAP pipes in order to prevent possible fuel and/or EVAP system contamination.

    9. Object Number: 1789403 Size: SH
  9. Loosen the fuel fill pipe hose clamp (3) at the fuel tank.
  10. Separate the fuel fill pipe hose from the fuel tank.
  11. Disconnect the fuel tank EVAP emission canister vent pipe quick connect fitting (2) from the fuel tank fill EVAP emission pipe. Refer to Plastic Collar Quick Connect Fitting Service.
  12. Remove the fuel tank fill pipe.

Installation Procedure

    Object Number: 1789403 Size: SH
  1. Install the fuel tank fill pipe.
  2. Install the fuel fill pipe hose to the fuel tank.
  3. Connect the fuel tank EVAP emission canister vent pipe quick connect fitting (2) from the fuel tank fill EVAP emission pipe. Refer to Plastic Collar Quick Connect Fitting Service.

    4. Notice: Refer to Fastener Notice in the Preface section.

  4. Tighten the fuel fill pipe hose clamp (3) at the fuel tank.

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


    Object Number: 1789402 Size: SH
  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. Object Number: 1791673 Size: SH
  8. Install the fuel tank fill pipe bolt (2) to the underbody side rail.

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

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

    11. 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.
    14. 13.1. Turn ON the ignition, with the engine OFF for 10 seconds.
    13.2. Turn OFF the ignition for 10 seconds.
    13.3. Turn ON the ignition, with the engine OFF.
    13.4. Inspect for fuel leaks.

Filler Tube Replacement Maxx

Removal Procedure

Important: Clean the fuel and evaporative emission (EVAP) connections and surrounding areas prior to disconnecting the lines in order the avoid possible system contamination.


    Object Number: 1791673 Size: SH
  1. Remove the fuel fill cap.
  2. Drain the fuel tank. Refer to Fuel Tank Draining .
  3. Remove the fuel tank fill pipe bolt (1) from the fuel tank fill pipe housing.
  4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  5. Remove the fuel tank fill pipe bolt (2) from the underbody side rail.

    6. Object Number: 1789402 Size: SH
  6. Disconnect the fuel tank fuel feed pipe quick connect fitting (1) from the chassis fuel feed pipe (3). Refer to Plastic Collar Quick Connect Fitting Service .
  7. Disconnect the fuel tank EVAP pipe quick connect fitting (2) from the chassis EVAP pipe (4). Refer to Plastic Collar Quick Connect Fitting Service .
  8. Cap the chassis fuel and EVAP pipes in order to prevent possible fuel and/or EVAP system contamination.

    9. Object Number: 1795261 Size: SH
  9. Loosen the fuel fill pipe hose clamp (3) at the fuel tank.
  10. Separate the fuel fill pipe hose from the fuel tank.
  11. Disconnect the fuel tank fill EVAP emission pipe quick connect fitting (2) from the fuel tank vent pipe (1). Refer to Plastic Collar Quick Connect Fitting Service .
  12. Remove the fuel tank fill pipe.

Installation Procedure

    Object Number: 1795261 Size: SH
  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. Notice: Refer to Fastener Notice in the Preface section.

  4. Tighten the fuel fill pipe hose clamp (3) at the fuel tank.

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


    Object Number: 1789402 Size: SH
  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. Object Number: 1791673 Size: SH
  8. Install the fuel tank fill pipe bolt (2) to the underbody side rail.

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

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

    11. 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.
    14. 13.1. Turn ON the ignition, with the engine OFF for 10 seconds.
    13.2. Turn OFF the ignition for 10 seconds.
    13.3. Turn ON the ignition, with the engine OFF.
    13.4. Inspect for fuel leaks.