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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 840 (ENGINE CONTROLS AND FUEL - 2.2L - REPAIR INSTRUCTIONS)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 2010 Pontiac G5 and 2010 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of 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 (NU6)  or Fuel Pump Module Replacement (NT7) .
  2. Use a suitable jack to 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. CAUTION: Refer to Fastener Caution .
  7. Tighten the fuel tank strap bolts to 25 N.m (18 lb ft).
    8. Fig 2: Identifying Exhaust Muffler
    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 EVAP Canister Harness & Fuel Tank Harness Electrical Connector
    GM1652166Courtesy of GENERAL MOTORS CORP.
  9. Connect the fuel tank harness electrical connector (1) to the fuel tank pressure sensor.
  10. Connect the fuel tank harness electrical connector (2) to the EVAP canister vent solenoid valve.
  11. Install the harness retainers to the underbody.
    12. Fig 4: View Of Fuel Tank Harness Electrical Connectors
    GM1656962Courtesy of GENERAL MOTORS CORP.
  12. Connect the fuel tank harness electrical connectors (1 and 3) to the body harness pass thru connector (2).
    13. Fig 5: View Of Fuel Tank Vent Line Quick Connect Fitting
    GM1656960Courtesy of GENERAL MOTORS CORP.
  13. Remove the cap or plug from the fuel tank and vent line openings.
  14. 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).
    15. CAUTION: Refer to Component Fastener Tightening Caution .
  15. Tighten the fuel fill hose clamp (3) to 4.5 N.m (40 lb in).
  16. Connect the fuel tank vent line quick connect fitting (2) to the fill pipe recirculation line. Refer to Plastic Collar Quick Connect Fitting Service .
    17. Fig 6: View Of Fuel Tank Evaporative Emission Line Quick Connect Fittings
    GM1656958Courtesy of GENERAL MOTORS CORP.
  17. Remove the caps or plugs from the EVAP lines.
  18. Connect the fuel tank EVAP line quick connect fittings (2, 3) to the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
    19. Fig 7: View Of Fuel Pump Module Fuel Feed And Return Line Quick Connect Fittings
    GM1656956Courtesy of GENERAL MOTORS CORP.
  19. Remove the caps or plugs from the fuel pump module fuel feed and return lines.
  20. Remove the caps or plugs from the fuel filter feed and return line fittings.
  21. Connect the fuel pump module fuel feed (2) and return (1) line quick connect fittings to the fuel filter. Refer to Plastic Collar Quick Connect Fitting Service .
  22. Lower the vehicle.
  23. Refill the fuel tank.
  24. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  25. 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.