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 ...
See also:
Chevrolet Cobalt Owners Manual. Exterior Lighting
The lever is on the left side of the steering column.
: Turns on the headlamps,
parking lamps, and
taillamps.
: Turns on the parking lamps
and taillamps only.
AUTO: Automatically turns on the Daytime Running
Lamps (DRL) during daytime, and the headlamps,
parking lamps, and taillamps at n ...
Chevrolet Cobalt Owners Manual
Chevrolet Cobalt Service Manual
Passkey Module
2007-10 Cobalt & G5