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.
    Passkey 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 ...

    2007-10 Cobalt & G5
    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 Service & Repair Manual. Engine Oil Light, Diagnosis & Testing
    1. Understand and validate customer concern. Inspect visible system components for obvious damage or conditions that may cause concern. 2. Inspect for related bulletins, recall/field actions and preliminary information. ...

    Chevrolet Cobalt Owners Manual

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