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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 692 (ENGINE CONTROL SYSTEM & FUEL SYSTEM - 2.4L - INTRODUCTION (2 OF 2))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 2008 Pontiac G5 and 2008 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Fuel Tank Vent Line Quick Connect Fitting
    GM1656960Courtesy of GENERAL MOTORS CORP.
  1. Remove the caps or plugs from the fuel tank opening and vent line.
  2. Install 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).
    3. NOTE: Refer to Fastener Notice .
  3. Tighten the fuel fill hose clamp (3) at the fuel tank.

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

  4. Connect the fuel tank vent line quick connect fitting (2) to the fill pipe recirculation line. Refer to Plastic Collar Quick Connect Fitting Service .
    5. Fig 2: View Of Fuel Fill Pipe Lower Bolt
    GM1656988Courtesy of GENERAL MOTORS CORP.
  5. Install the fuel fill pipe lower bolt.

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

    6. Fig 3: View Of Fuel Fill Vent Pipe Quick Connect Fitting
    GM1656958Courtesy of GENERAL MOTORS CORP.
  6. Remove the cap or plug from the EVAP canister fitting.
  7. Connect the fuel fill vent pipe quick connect fitting (1) to the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
  8. Lower the vehicle.
  9. Install the fuel fill pocket. Refer to Fuel Tank Filler Pipe Housing Replacement .
  10. Refill the fuel tank.
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.