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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 166 (ENGINE CONTROLS - 3.5L (L66) INTRODUCTION)REPAIR INSTRUCTIONSFILLER TUBE 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 Vue. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the rubber grommet onto the fuel filler pipe.
  2. Position the filler pipe into the wheel opening with the top of the pipe within the body panel opening.
    Fig 1: Fuel Neck Attachment & Bolt
    GM927722Courtesy of GENERAL MOTORS CORP.
  3. Install the fuel filler hose onto the fuel tank inlet.
    Fig 2: View Of Fuel Filler Pipe, EVAP Vent & Fresh Air Hoses At Fuel Tank
    GM1347586Courtesy of GENERAL MOTORS CORP.
  4. Install the fuel filler pipe intermediate bracket bolt. Do not tighten at this time.
    Fig 3: View Of Fuel Pipe Intermediate Bracket Bolt
    GM932666Courtesy of GENERAL MOTORS CORP.
  5. Lower the vehicle and install the filler pipe to upper fuel fill pipe support bracket by moving the fuel filler neck up and to the right, toward the front of the vehicle.
    Fig 4: Fuel Neck Attachment & Bolt
    GM927722Courtesy of GENERAL MOTORS CORP.
    6. NOTE: Refer to Fastener Notice in Cautions and Notices.
  6. Tighten the fuel fill pipe-to-body bolt.

    Tighten:  Tighten the bolt to 3 N.m (27 lb. in.).

  7. Install the fuel cap.
  8. Raise the vehicle to a comfortable working height.
    9. IMPORTANT: Ensure that the fuel pipe connecting hose is installed until it touches the fuel tank body. The hose clamp should be located within 13 mm (1/2 in) of the end of the connecting hose.
  9. Tighten the hose clamp on the filler pipe-to-fuel tank connecting hose.

    Tighten:  Tighten the fuel fill neck-to-fuel tank clamp to 5 N.m (44 lb. in.).

  10. Connect the fuel fill pipe vent tube and fresh air hose.
  11. Tighten the intermediate bracket bolt.

    Tighten:  Tighten the bolt to 10 N.m (89 lb. in.).

    Fig 5: View Of Fuel Pipe Intermediate Bracket Bolt
    GM932666Courtesy of GENERAL MOTORS CORP.
  12. Install the inner wheelhouse liner. Refer to Wheelhouse Liner Panel Replacement - Rear in Body Front End.
  13. Install the wheel and tire. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  14. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  15. Lower the vehicle from the hoist.
  16. Perform the Service Bay Diagnostic Test for the EVAP emission system using the scan tool. This test will verify the integrity of the vapor handling areas of the fuel system.
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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.