Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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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 INSTRUCTIONSFUEL TANK REPLACEMENTREMOVAL PROCEDURE
2006 Chevrolet Cobalt SS, 4D Sedan, Standard
Removal Procedure
2006 Chevrolet Cobalt SS, 4D Sedan, StandardSECTION Removal 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.
CAUTION:
Refer to Gasoline/Gasoline Vapors Caution
.
- Relieve the fuel system pressure. Refer to Fuel Pressure Relief (With CH 48027) or Fuel Pressure Relief (Without CH 48027) .
- Drain the fuel tank. Refer to Fuel Tank Draining .
- Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
- Disconnect the fuel pump module fuel feed (2) and return (1) line quick connect fittings from the fuel filter. Refer to Plastic Collar Quick Connect Fitting Service .
- Cap or plug the fuel filter feed and return line fittings in order to prevent fuel loss and/or system contamination.
- Cap or plug the fuel pump module feed and return lines in order to prevent fuel loss and/or system contamination.
- Disconnect the fuel tank evaporative emission (EVAP) line quick connect fittings (2, 3) from the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
- Cap or plug the EVAP lines and canister fittings in order to prevent system contamination.
- Disconnect the fuel tank vent line quick connect fitting (2) from the fill pipe recirculation line. Refer to Plastic Collar Quick Connect Fitting Service .
- Loosen the fuel fill hose clamp (3) at the fuel tank.
- Remove the fuel fill hose from the fuel tank.
- Cap or plug the fuel tank opening and vent line in order to prevent fuel loss and/or system contamination.
- Disconnect the fuel tank harness electrical connectors (1 and 3) from the body harness pass thru connector (2).
- Disconnect the fuel tank harness electrical connector (1) from the fuel tank pressure sensor.
- Disconnect the fuel tank harness electrical connector (2) from the EVAP canister vent solenoid valve.
- Remove the harness retainers from the underbody.
- Release the exhaust muffler assembly insulators from the underbody hangers and slowly lower the exhaust, allowing it to rest on the rear axle beam.
- Use a suitable jack to support the fuel tank during the fuel tank strap and tank removal.
- Remove the left (L) fuel tank strap bolts and strap.
- Remove the right (R) fuel tank strap bolts and strap.
- In order to clear the exhaust muffler assembly, slowly lower the right side of the fuel tank. Use care when feeding the fuel, EVAP lines, and electrical harness around rear axle.
- Once the fuel tank is clear of the right frame rail, remove the fuel tank down and toward the right side of the vehicle.
- If the fuel tank is be replaced, remove the fuel pump module. Refer to Fuel Pump Module Replacement .
RENDER: 1.0x
NO RELATED
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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.