Chevrolet Cobalt Service & Repair Manual: 2007-10 Cobalt & G5
w/2.0L & 2.4L Engines
| Warning: Gasoline or gasoline
vapors are highly flammable. A fire could occur if an ignition source is
present. Never drain or store gasoline or diesel fuel in an open container,
due to possibility of fire or explosion. Have a dry chemical (Class B) fire
extinguisher nearby. |
| Remove fuel tank cap and relieve
fuel system pressure before servicing fuel system in order to reduce risk
of personal injury. After you relieve fuel system pressure, a small amount
of fuel may be released when servicing fuel lines, fuel injection pump,
or connections. In order to reduce risk of personal injury, cover fuel system
components with a shop towel before disconnection. This will catch any fuel
that may leak out. Place towel in an approved container when disconnection
is complete. |
| 1. |
Keep a shop cloth and a container ready
to capture any spilled fuel. |
| 2. |
Relieve fuel system pressure. |
| 3. |
Raise and support vehicle. |
| 4. |
Remove fuel filter bracket. |
| 5. |
Disconnect fuel filter from engine
fuel feed pipe. |
| 6. |
Tilt fuel filter downward and drain
off fuel into an approved fuel container. |
| 7. |
Drain any remaining fuel into an approved
fuel container. |
| 8. |
Discard fuel filter into an approved
container. |
|
w/2.2L Engine
Federal Emission Models
| Warning: Gasoline or gasoline
vapors are highly flammable. A fire could occur if an ignition source is
present. Never drain or store gasoline or diesel fuel in an open container,
due to possibility of fire or explosion. Have a dry chemical (Class B) fire
extinguisher nearby. |
| Remove fuel tank cap and relieve
fuel system pressure before servicing fuel system in order to reduce risk
of personal injury. After you relieve fuel system pressure, a small amount
of fuel may be released when servicing fuel lines, fuel injection pump,
or connections. In order to reduce risk of personal injury, cover fuel system
components with a shop towel before disconnection. This will catch any fuel
that may leak out. Place towel in an approved container when disconnection
is complete. |
| 1. |
Keep a shop cloth and a container ready
to capture any spilled fuel. |
| 2. |
Relieve fuel system pressure. |
| 3. |
Raise and support vehicle. |
| 4. |
Remove fuel filter bracket. |
| 5. |
Disconnect fuel filter from engine
fuel feed pipe. |
| 6. |
Tilt fuel filter downward and drain
off fuel into an approved fuel container. |
| 7. |
Drain any remaining fuel into an approved
fuel container. |
| 8. |
Discard fuel filter into an approved
container. |
|
California Emission Models
| Warning: Gasoline or gasoline
vapors are highly flammable. A fire could occur if an ignition source is
present. Never drain or store gasoline or diesel fuel in an open container,
due to possibility of fire or explosion. Have a dry chemical (Class B) fire
extinguisher nearby. |
| Remove fuel tank cap and relieve
fuel system pressure before servicing fuel system in order to reduce risk
of personal injury. After you relieve fuel system pressure, a small amount
of fuel may be released when servicing fuel lines, fuel injection pump,
or connections. In order to reduce risk of personal injury, cover fuel system
components with a shop towel before disconnection. This will catch any fuel
that may leak out. Place towel in an approved container when disconnection
is complete. |
| Warning: In order to reduce
risk of fire and personal injury that may result from a fuel leak, always
replace fuel sender gasket when installing fuel sender assembly. |
| 1. |
Relieve fuel system pressure. |
| 2. |
Remove fuel filler cap. |
| 3. |
Drain fuel tank into a suitable container. |
| 4. |
Raise and support vehicle. |
| 5. |
Disconnect fuel tank line quick connect
fitting from fuel feed line. |
| 6. |
Cap or plug fuel feed line and fuel
tank line in order to prevent fuel loss and/or system contamination. |
| 7. |
Disconnect fuel tank evaporative emission
(EVAP) line quick connect fitting from EVAP canister. |
| 8. |
Disconnect fuel fill pipe fresh air
line quick connect fitting from EVAP canister. |
| 9. |
Cap or plug EVAP/fresh air lines and
canister fittings in order to prevent system contamination. |
| 10. |
Disconnect fuel tank vent line quick
connect fitting from fill pipe recirculation line. Do not pry on
fuel filler hose or damage to fuel tank may occur. |
| 11. |
Loosen fuel fill hose clamp at fuel
tank. |
| 12. |
Cap or plug fuel tank opening and vent
line in order to prevent fuel loss and/or system contamination. |
| 13. |
Disconnect fuel tank harness electrical
connectors from body harness pass through connector. |
| 14. |
Disconnect fuel tank harness electrical
connector from fuel tank pressure sensor. |
| 15. |
Disconnect fuel tank harness electrical
connector from EVAP canister vent solenoid valve. |
| 16. |
Remove harness retainers from underbody. |
| 17. |
Release exhaust muffler assembly insulators
from underbody hangers and slowly lower exhaust, allowing it to
rest on rear axle beam. |
| 18. |
Remove fuel tank harness clips from
underbody. |
| 19. |
Support fuel tank, using suitable jack
during fuel tank strap and tank removal. |
| 20. |
Remove fuel tank strap bolts and straps. |
| 21. |
In order to clear exhaust muffler assembly,
slowly lower righthand side of fuel tank. Use care when feeding
fuel, EVAP lines and electrical harness around rear axle. |
| 22. |
Once fuel tank is clear of righthand
frame rail, remove fuel tank down and toward righthand side of vehicle. |
| 23. |
Unlock fuel sender lock ring, using
suitable fuel sender lock ring wrench. |
| 24. |
Slowly lift fuel pump flange up until
quick connect fittings and fuel level sensor electrical connector
are just visible. |
| 25. |
Disconnect fuel level sensor electrical
connector from fuel pump flange. |
| 26. |
Disconnect fuel tank vent valve and
fuel filter quick connect fittings from fuel pump flange. |
| 27. |
Remove fuel pump flange lock ring and
fuel pump flange. If required, remove lock ring from flange. |
| 28. |
Remove and discard fuel pump flange
seal. |
| 29. |
Squeeze fuel pump quick connect fitting
retainer together in order to remove fitting from fuel filter. |
| 30. |
Reposition fuel pump line. |
| 31. |
Rotate fuel pump to lefthand until
tab is aligned with opening in fuel pump module. |
| 32. |
Remove fuel pump from fuel pump module. |
|
On models equipped with the Passkey
Theft Deterrent System, a new password must be learned by the PCM when the
BCM/PCM has been replaced. When the PCM is replaced, the EEPROM calibratio ...
Warning: Gasoline or gasoline
vapors are highly flammable. A fire could occur if an ignition source is
present. Never drain or store gasoline or diesel fuel in an open container,
du ...
Chevrolet Cobalt Owners Manual
Chevrolet Cobalt Service Manual
Passkey Module
2007-10 Cobalt & G5