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How To Replace Fuel Filler Neck 97-03 Chevy Malibu

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How To Replace Fuel Filler Neck 97-03 Chevy Malibu

Created on: 2021-01-16

How to repair, install, fix, change or replace a rusted, damaged, rotted, bent or leaking fuel tank filler neck on Chevy Malibu, years 97, 98, 99, 00, 01, 02, and 03.

  1. step 1 :Removing the Fuel Filler Neck
    • Open the fuel door
    • Twist off the gas cap
    • Remove the two T20 Torx screws from the fuel filler neck
    • If the screws do not remove easily, pull them out with pliers
    • Pull out the locking clips
    • Loosen the fuel hose clamp with a flat blade screwdriver
    • Separate the hose from the filler neck
    • Remove the 10mm bolt from the filler neck bracket
    • Pull the filler neck out of the gas compartment from behind
    • Pull out the filler neck insert
    • Pull the filler neck out through the gas compartment
  2. step 2 :Installing the New Fuel Filler Neck
    • Push the new filler neck into place through the gas compartment
    • Push the filler neck insert into place
    • Insert the locking clips onto the filler neck
    • Insert the two T20 screws into the filler neck
    • Twist on the gas cap
    • Close the fuel door
    • Insert the 10mm bolt into the filler neck bracket
    • Position the fuel hose clamp
    • Connect the hose to the filler neck
    • Tighten the hose clamp with a flat blade screwdriver

Tools needed for replacement

  • General Tools

    Jack Stands

    Floor Jack

  • Pliers, Cutters & misc Wrenches

    Slip-Joint Pliers

  • Ratchets & Related

    Ratchet

  • Screwdrivers & Related

    Flat Blade Screwdriver

  • Sockets - Metric

    10mm Socket

  • Star Drivers & Sockets

    T20 Driver

Installation Video
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In this video we're going to replace the fuel filler neck on this '01 Malibu, same as any '97 to '03. If you're getting a check engine light and it says that you need to tighten the gas cap, and you do tighten the gas cap and it doesn't help, that's usually because the fuel filler neck rusts out and it needs to be replaced. The tools you'll need are a jack and jack stands, T20 Torx driver or pair of pliers, flat blade screwdriver, and a 10 mm socket with ratchet and extension.

Open your gas compartment. Remove your cap with the two T20 screws here. What those screws are is just little locking clips so you can try and pull them out counterclockwise. They may or may not come out. If you have to just use a pair of pliers and you can pull them out and then reach up underneath and push the clips out and pull them up and out.

Your fuel filler neck connects right here. We're going to use a regular screwdriver and loosen up that clamp. You just want to grab onto that hose and just twist it and pull it and break it free and then pull it off. Now, up underneath, in the rear wheel carriage area, there is a hole and that hole leads up to a little 10mm bolt that holds the fuel filler neck on by a bracket. Remove that 10mm bolt. Pull this back out and pull that insert out and your filler neck comes right out like that.

Put the new filler neck down and in. Make sure it goes in through there. From underneath, you've just got to wriggle it, so this comes all the way through. Here, we put those little clips back in and then put the little locking screws back in as well. Here's a little fast motion. I put the bolt up in there with my extension and socket. With my right hand I'm pulling it in toward the middle of the car to get the bolt started and then put my ratchet back on there and tighten it up. You don't have to get it extremely tight, but it wants to be nice and firm. Don't over tighten it. Now take your clamp, make sure you put it up there so you're going to have a good angle at getting to the screw. Connect the hose. We'll fast forward that as we tighten up that clamp.

We hope this video helps you out. Brought to you by www.1AAuto.com, your source for quality replacement parts and the best service on the Internet. Please feel free to call us toll-free, 888-844-3393. We're the company that's here for you on the Internet and in person.

Tools needed for replacement:

    General Tools

  • Jack Stands
  • Floor Jack

  • Pliers, Cutters & misc Wrenches

  • Slip-Joint Pliers

  • Ratchets & Related

  • Ratchet

  • Screwdrivers & Related

  • Flat Blade Screwdriver

  • Sockets - Metric

  • 10mm Socket

  • Star Drivers & Sockets

  • T20 Driver

1997 - 1997  Chevrolet  Malibu
1997 - 1997  Oldsmobile  Cutlass
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