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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 12 (ENGINE CONTROLS - INTRODUCTION)REPAIR INSTRUCTIONSFUEL TANK REPLACEMENTINSTALLATION PROCEDURE
2006 Chevrolet Cobalt SS, 4D Sedan, Standard

Installation Procedure

2006 Chevrolet Cobalt SS, 4D Sedan, StandardSECTION Installation Procedure
WARNING: This page is about a different car, the 2005 Saturn L300. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Positioning Fuel Tank, Heat Shield & Straps Under Vehicle
    GM892354Courtesy of GENERAL MOTORS CORP.
  1. With the aid of an assistant, position the fuel tank with the heat shield and straps under the vehicle.
  2. Attach the electrical connectors to the fuel pump and the tank pressure sensor.
    3. NOTE: Refer to Fastener Notice in Cautions and Notices.
  3. Reposition the fuel tank mounting straps and shield around the tank and install the strap mounting bolts to the underbody.

    Tighten:  Tighten the fuel tank mounting strap to 20 N.m (15 lb ft).

    4. NOTE: Replace plastic fuel line retainers whenever the fuel supply or return line is disconnected at the fuel rail. Install the new retainer into the female cavity of the connection. Care must be taken to ensure that the locking tab is centered in the window of the female cavity. Firmly press the female connection onto the male end until a click is heard, then pull back to confirm engagement. Pinched, kinked, or damaged fuel lines must be replaced.
  4. Install new retainers into the female portion of the quick-connect fitting on the underbody fuel and EVAP canister purge lines.
    5. IMPORTANT: Lubricate the male ends of the filter with clean engine oil to ease installation.
  5. Connect the fuel feed, return, and vapor lines.
  6. Install the fuel tank grounding strap attachment nut located near the fuel filler neck.

    Tighten:  Tighten the fuel tank grounding strap attachment to 4.5 N.m (35 lb in).

    7. Fig 2: Removing/Installing Fuel Filler Pipe Lower Bracket Attaching Screw
    GM893228Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

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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.