LEMON Manuals: Even more car manuals for everyone
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) >> Removal Procedure

Removal 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.
CAUTION: Refer to Gasoline/Gasoline Vapors Caution .
    Fig 1: Identifying Fuel Fill Vent Pipe Quick Connect Fitting
    GM1651435Courtesy of GENERAL MOTORS CORP.
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .
  2. Drain the fuel tank. Refer to Fuel Tank Draining .
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  4. Disconnect the fuel tank line quick connect fitting from the fuel feed line. Refer to Plastic Collar Quick Connect Fitting Service .
  5. Cap or plug the fuel feed line and the fuel tank line in order to prevent fuel loss and/or system contamination.
  6. Disconnect the fuel tank evaporative emission (EVAP) line quick connect fitting (3) from the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
  7. Disconnect the fuel fill pipe fresh air line quick connect fitting (2) from the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
  8. Cap or plug the EVAP/fresh air lines and canister fittings in order to prevent system contamination.
    9. Fig 2: View Of Fuel Tank Vent Line Quick Connect Fitting
    GM1752397Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the fuel tank vent line quick connect fitting (1) from the fill pipe recirculation line. Refer to Plastic Collar Quick Connect Fitting Service .
  10. Loosen the fuel fill hose clamp (2) at the fuel tank.
  11. Remove the fuel fill hose from the fuel tank.
  12. Cap or plug the fuel tank opening and vent line in order to prevent fuel loss and/or system contamination.
    13. Fig 3: View Of Fuel Tank Harness Electrical Connectors
    GM1656962Courtesy of GENERAL MOTORS CORP.
  13. Disconnect the fuel tank harness electrical connectors (1 and 3) from the body harness pass thru connector (2).
    14. Fig 4: View Of Fuel Tank Harness Electrical Connector
    GM1652166Courtesy of GENERAL MOTORS CORP.
  14. Disconnect the fuel tank harness electrical connector (1) from the fuel tank pressure sensor.
  15. Disconnect the fuel tank harness electrical connector (2) from the EVAP canister vent solenoid valve.
  16. Remove the harness retainers from the underbody.
    17. Fig 5: Identifying Exhaust Muffler
    GM1651437Courtesy of GENERAL MOTORS CORP.
  17. Release the exhaust muffler assembly insulators from the underbody hangers and slowly lower the exhaust, allowing it to rest on the rear axle beam.
    18. Fig 6: View Of Fuel Tank Harness Clips
    GM1752249Courtesy of GENERAL MOTORS CORP.
  18. Remove the fuel tank harness clips from the underbody.
  19. Use a suitable jack to support the fuel tank during the fuel tank strap and tank removal.
  20. Remove the left (L) fuel tank strap bolts and strap.
  21. Remove the right (R) fuel tank strap bolts and strap.
  22. 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.
  23. Once the fuel tank is clear of the right frame rail, remove the fuel tank down and toward the right side of the vehicle.
  24. If the fuel tank is be replaced, remove the following components:
scientia non olet · About LEMON Manuals