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Home >> Chevrolet >> 2006 >> Cobalt LTZ >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 2 (Engine Controls - 2.4L - Introduction (2 Of 2)) >> Repair Instructions >> Fuel Tank Replacement >> Removal Procedure

Removal Procedure

WARNING: This page is about a different variant/trim than selected.
CAUTION: Refer to Gasoline/Gasoline Vapors Caution .
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
  2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure .
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
    4. Fig 1: Disconnecting Fuel Pump Module Fuel Feed
    GM1656956Courtesy of GENERAL MOTORS CORP.
  4. Disconnect the fuel pump module fuel feed (2) and return (1) line quick connect fittings from the fuel filter. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  5. Cap or plug the fuel filter feed and return line fittings in order to prevent fuel loss and/or system contamination.
  6. Cap or plug the fuel pump module feed and return lines in order to prevent fuel loss and/or system contamination.
    7. Fig 2: Disconnecting Fuel Tank Evaporative Emission Line Quick Connect Fittings
    GM1656958Courtesy of GENERAL MOTORS CORP.
  7. Disconnect the fuel tank evaporative emission (EVAP) line quick connect fittings (2, 3) from the EVAP canister. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  8. Cap or plug the EVAP lines and canister fittings in order to prevent system contamination.
    9. Fig 3: Disconnecting Fuel Tank Vent Line Quick Connect Fitting
    GM1656960Courtesy of GENERAL MOTORS CORP.
  9. Disconnect the fuel tank vent line quick connect fitting (2) from the fill pipe recirculation line. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
  10. Loosen the fuel fill hose clamp (3) 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 4: Disconnecting Fuel Tank Harness Electrical Connectors
    GM1656962Courtesy of GENERAL MOTORS CORP.
  13. Disconnect the fuel pump module harness electrical connector (3) from the body harness pass thru connector (2).
    14. Fig 5: Identifying Exhaust Muffler
    GM1651437Courtesy of GENERAL MOTORS CORP.
  14. Release the exhaust muffler assembly insulators from the underbody hangers and slowly lower the exhaust, allowing it to rest on the rear axle beam.
    15. Fig 6: Removing Left Fuel Tank Strap Bolts And Straps
    GM1656964Courtesy of GENERAL MOTORS CORP.
  15. Have an assistant support the fuel tank during the fuel tank strap and tank removal.
  16. Remove the left (L) fuel tank strap bolts and strap.
  17. Remove the right (R) fuel tank strap bolts and strap.
  18. 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.
  19. Once the fuel tank is clear of the right frame rail, remove the fuel tank down and toward the right side of the vehicle.
  20. If the fuel tank is be replaced, remove the fuel pump module. Refer to Fuel Pump Module Replacement .
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