Cobalt 2006-2008, G5 2007

Removal & Installation

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2.0L, 2.2L, 2.4L Engines-Except 2.2L California Partial Zero Emission Vehicles (PZEV)



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
    NOTE
    Keep a shop cloth and a container ready to capture any spilled fuel.

  4.  
  5. Relieve the fuel system pressure. Refer to Relieving Fuel System Pressure.
  6.  
  7. Raise and support the vehicle.

    Click image to see an enlarged view

    Fig. Location of the fuel filter, bracket bolt, and filter disconnect from the engine fuel feed pipe

  8.  
  9. Remove the fuel filter bracket bolt.
  10.  
  11. Disconnect the fuel filter from the engine fuel feed pipe (1).
  12.  
  13. Tilt the fuel filter downward and drain off the fuel into an approved fuel container.
  14.  
  15. Disconnect the fuel tank feed and return hose fittings from the fuel filter.
  16.  
  17. Drain any remaining fuel into an approved fuel container.
  18.  
  19. Discard the fuel filter into an approved container.
  20.  

To install:

  1. Remove the protective caps from the new fuel filter.
  2.  
  3. Connect the fuel tank feed and return hose fittings to the fuel filter.
  4.  
  5. Connect the fuel filter to the engine feed fuel pipe.
  6.  
  7. Install the fuel filter bracket bolt. Tighten the bolt to 89 inch lbs. (10 Nm).
  8.  
  9. Lower the vehicle.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Inspect for fuel leaks using the following procedure:
    1. Turn the ignition switch ON, but do not start the engine. Wait 2 seconds.
    2.  
    3. Turn the ignition switch OFF and wait 10 seconds.
    4.  
    5. Turn the ignition switch ON, but do not start the engine.
    6.  
    7. Inspect for fuel leaks.
    8.  

  14.  

2.2L Engine California Partial Zero Emission Vehicles (PZEV)



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
    CAUTION
    In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.

  4.  
  5. Remove the fuel tank. Refer to Fuel Tank removal and installation.
  6.  
  7. Using tool J 45722, unlock the fuel sender lock ring.

    Click image to see an enlarged view

    Fig. Lift the fuel pump flange up until the quick connect fittings, fuel pump electrical connector, and fuel level sensor electrical connector are just visible

  8.  
  9. Slowly lift the fuel pump flange up until the quick connect fittings (1), fuel pump electrical connector, and fuel level sensor electrical connector are just visible.
  10.  
  11. Disconnect the fuel level sensor electrical connector from the fuel pump flange.
  12.  
  13. Disconnect the fuel tank vent valve and the fuel filter quick connect fittings (1) from the fuel pump flange.
  14.  
  15. Disconnect the fuel pump electrical connector from the fuel pump by depressing the lock tab on top of the electrical connector.

    Click image to see an enlarged view

    Fig. Exploded view of fuel tank with fuel pump flange lock & seal

  16.  
  17. Remove the fuel pump flange lock ring (1) and fuel pump flange (2). If required, remove the lock ring from the flange.
  18.  
  19. Remove and discard the fuel pump flange seal (3).
  20.  
  21. Squeeze the sides of the fuel pump fuel reservoir pump fuel strainer quick connect fitting together in order to remove the fitting from the fuel filter.
  22.  
  23. Reposition the fuel pump fuel reservoir pump fuel strainer line.

    Click image to see an enlarged view

    Fig. Squeeze the fuel pump quick connect fitting retainer (3) together to remove the fitting from the fuel filter. Reposition the fuel pump line and rotate the fuel filter to the left until the tab (2) is aligned with the opening in the fuel pump module

  24.  
  25. Squeeze the fuel pump quick connect fitting retainer (3) together in order to remove the fitting from the fuel filter.
  26.  
  27. Reposition the fuel pump line.
  28.  
  29. Rotate the fuel filter to the left until the tab (2) is aligned with the opening in the fuel pump module.
  30.  
  31. Remove the fuel filter from the fuel pump module.

    Click image to see an enlarged view

    Fig. Remove the fuel filter from the fuel pump module-2.2L Engine (RPO NU6)

  32.  

To install:

  1. Align the fuel filter tab with the opening in the fuel pump module.
  2.  
  3. Install the fuel filter to the fuel pump module.
  4.  
  5. Rotate the fuel filter to the right until the tab is locked into the fuel pump module.
  6.  
  7. Position the fuel pump line and install the fuel pump quick connect fitting to the fuel filter.
  8.  
  9. Install the fuel pump fuel reservoir pump fuel strainer quick connect fitting to the fuel filter.
  10.  
  11. Position a NEW fuel pump flange seal onto the fuel tank.
  12.  
  13. If required, install the lock ring onto the flange. Position the fuel pump flange and lock ring over the fuel tank opening.
  14.  
  15. Ensure that the fuel pump flange tab is aligned with the arrow on the fuel tank.
  16.  
  17. Connect the fuel tank vent valve and the fuel filter quick connect fittings to the fuel pump flange.
  18.  
  19. Connect the fuel pump electrical connector to the fuel pump.
  20.  
  21. Connect the fuel level sensor electrical connector to the fuel pump flange.
  22.  
  23. Slowly lower the fuel pump flange into the fuel tank.
  24.  
  25. Using tool J 45722, lock the fuel sender lock ring.
  26.  
  27. Install the fuel tank. Refer to Fuel Tank removal and installation.
  28.  

 
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