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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISENGINE PERFORMANCETESTING & DIAGNOSISENGINE CONTROLS - 2.4L - INTRODUCTION (2 OF 2)REPAIR INSTRUCTIONSFUEL TANK REPLACEMENTINSTALLATION PROCEDURE
2006 Chevrolet Cobalt SS, 4D Sedan, Standard

Installation Procedure

2006 Chevrolet Cobalt SS, 4D Sedan, StandardSECTION Installation Procedure
    Fig 1: Installing Left Fuel Tank Strap Bolts And Straps
    GM1656964Courtesy of GENERAL MOTORS CORP.
  1. If the fuel tank was replaced, install the fuel pump module. Refer to Fuel Pump Module Replacement .
  2. Have an assistant support the fuel tank during the fuel tank and strap installation.
  3. Install the left side of the fuel tank over the exhaust muffler assembly.
  4. Raise the right side of the fuel tank into position inboard of the right frame rail. Use care when feeding the fuel, EVAP lines, and electrical harness over the rear axle.
  5. Install the right (R) fuel tank strap and bolts.
  6. Install the left (L) fuel tank strap and bolts.
    7. NOTE: Refer to Fastener Notice .
  7. Tighten the fuel tank strap bolts.

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

    8. Fig 2: Tightening Fuel Tank Strap Bolts
    GM1651437Courtesy of GENERAL MOTORS CORP.
  8. Raise the exhaust muffler assembly into position and install the insulators to the underbody hanger.
    9. Fig 3: View Of Fuel Pump Module Harness Electrical Connector To Body Harness Pass Thru Connector
    GM1656962Courtesy of GENERAL MOTORS CORP.
  9. Connect the fuel pump module harness electrical connector (3) to the body harness pass thru connector (2).
    10. Fig 4: Disconnecting Fuel Tank Vent Line Quick Connect Fitting
    GM1656960Courtesy of GENERAL MOTORS CORP.
  10. Remove the cap or plug from the fuel tank and vent line openings.
  11. Connect the fuel fill hose to the fuel tank. Align the "D" notch on the fill hose (1) with the "D" notch on the fuel tank (1).
    12. NOTE: Refer to Component Fastener Tightening Notice .
  12. Tighten the fuel fill hose clamp (3).

    Tighten:  Tighten the clamp to 4.5 N.m (40 lb in).

    13. Fig 5: Connecting Fuel Fill Vent Pipe Quick Connect Fittings
    GM1656958Courtesy of GENERAL MOTORS CORP.
  13. Connect the fuel tank vent line quick connect fitting (2) to the fill pipe recirculation line. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  14. Remove the caps or plugs from the EVAP lines.
  15. Connect the fuel tank EVAP line quick connect fittings (2, 3) to the EVAP canister. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  16. Remove the caps or plugs from the fuel pump module fuel feed and return lines.
  17. Remove the caps or plugs from the fuel filter feed and return line fittings.
    18. Fig 6: View Of Fuel Pump Module Fuel Feed And Return Line Quick Connect Fittings
    GM1656956Courtesy of GENERAL MOTORS CORP.
  18. Connect the fuel pump module fuel feed (2) and return (1) line quick connect fittings to the fuel filter. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  19. Lower the vehicle.
  20. Refill the fuel tank.
  21. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure .
  22. Inspect for fuel leaks using the following procedure:
    1. Turn ON the ignition, with the engine OFF for 2 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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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.