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Home >> Chevrolet >> 2006 >> Cobalt LTZ >> Repair and Diagnosis >> External Pages >> Different car >> Section 679 (Engine Controls And Fuel - 2.2L (L61) - Introduction (2 Of 2)) >> Repair Instructions >> Fuel Tank Replacement (RPO NU6) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2007 Pontiac G5 Pursuit, 2007 Pontiac G5, and 2007 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View Of Fuel Tank Components
    GM1752249Courtesy of GENERAL MOTORS CORP.
  1. If the fuel tank was replaced, install the following components:
  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. NOTE: Refer to Fastener Notice .
  7. Tighten the fuel tank strap bolts.

    Tighten:  Tighten the bolts to 25 N.m (18 lb ft).

  8. Install the fuel tank harness clips to the underbody.
    9. Fig 2: Identifying Exhaust Muffler
    GM1651437Courtesy of GENERAL MOTORS CORP.
  9. Raise the exhaust muffler assembly into position and install the insulators to the underbody hanger.
    10. Fig 3: View Of EVAP Canister Harness Electrical Connector
    GM1652166Courtesy of GENERAL MOTORS CORP.
  10. Connect the fuel tank harness electrical connector (1) to the fuel tank pressure sensor.
  11. Connect the fuel tank harness electrical connector (2) to the EVAP canister vent solenoid valve.
  12. Install the harness retainers to the underbody.
    13. Fig 4: View of fuel tank harness electrical connectors
    GM1656962Courtesy of GENERAL MOTORS CORP.
  13. Connect the fuel tank harness electrical connectors (1 and 3) to the body harness pass thru connector (2).
    14. Fig 5: View Of Cap Or Plug
    GM1752397Courtesy of GENERAL MOTORS CORP.
  14. Remove the cap or plug from the fuel tank and vent line openings.
  15. Connect the fuel fill hose to the fuel tank.
    16. NOTE: Refer to Component Fastener Tightening Notice .
  16. Tighten the fuel fill hose clamp (2).

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

  17. Connect the fuel tank vent line quick connect fitting (1) to the fill pipe recirculation line. Refer to Plastic Collar Quick Connect Fitting Service .
    18. Fig 6: View Of Caps Or Plug
    GM1651435Courtesy of GENERAL MOTORS CORP.
  18. Remove the caps or plug from the EVAP/fresh air lines and canister fittings.
  19. Connect the fuel fill pipe fresh air line quick connect fitting (2) to the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
  20. Connect the fuel tank EVAP line quick connect fitting (3) to the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
  21. Remove the cap or plug from the fuel feed line and the fuel tank line.
  22. Connect the fuel tank line quick connect fitting to the fuel feed line. Refer to Plastic Collar Quick Connect Fitting Service .
  23. Lower the vehicle.
  24. Refill the fuel tank.
  25. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  26. 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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