Cobalt 2006-2008, G5 2007

Relieving Fuel System Pressure

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2.0L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
    CAUTION
    Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.

  2.  
  3. Turn the ignition OFF.
  4.  
  5. Disconnect the battery negative cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine.
  6.  
  7. Loosen the fuel filler cap to relieve the fuel tank vapor pressure.
  8.  
  9. Remove the cap from the fuel pressure service port.
  10.  
  11. Remove the engine identification cover nuts and cover.

    Click image to see an enlarged view

    Fig. Fuel pressure service port connection-2.0L engine

  12.  
  13. Connect fuel pressure gauge J 34730-1A, or equivalent, to the fuel pressure service port connection. Wrap a shop towel around the port while connecting the gage in order to avoid spillage.
    CAUTION
    Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion.

  14.  
  15. Install the bleed hose of the gauge into an approved fuel container.
  16.  
  17. Open the bleed valve on the gauge in order to bleed the fuel system pressure. The fuel connections are now safe for servicing.
  18.  
  19. Place a shop towel under the fuel pressure service port to catch any remaining fuel spillage.
  20.  
  21. Disconnect the gauge from the fuel pressure service port connection.
  22.  
  23. Drain any fuel remaining in the gage into an approved fuel container.
  24.  
  25. Install the cap to the fuel pressure service port.
  26.  

2.2L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
    CAUTION
    Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.



    Click image to see an enlarged view

    Fig. Fuel bleed procedure-2.2L engine

  2.  
  3. Turn the ignition OFF.
  4.  
  5. Disconnect the battery negative cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine.
  6.  
  7. Loosen the fuel filler cap to relieve the fuel tank vapor pressure.
  8.  
  9. Remove the cap from the fuel pressure service port.
  10.  
  11. Connect tool SA9127E or J 34730-1A to the fuel pressure service port connection. Wrap a shop towel around the port while connecting the gauge in order to avoid spillage.
    CAUTION
    Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion.

  12.  
  13. Install the bleed hose into an approved fuel container.
  14.  
  15. Open the bleed valve on the in order to bleed the fuel system pressure. The fuel connections are now safe for servicing.
  16.  
  17. Place a shop towel under the fuel pressure service port to catch any remaining fuel spillage.
  18.  
  19. Disconnect the gauge from the fuel pressure service port connection.
  20.  
  21. Drain any fuel remaining in the gauge into an approved fuel container.
  22.  
  23. Install the cap to the fuel pressure service port.
  24.  

2.4L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
    CAUTION
    Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.

  2.  

If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse.

  1. Remove the engine cover, if required.
  2.  
  3. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure.
  4.  
  5. Remove the fuel rail service port cap.
    CAUTION
    Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete.

  6.  
  7. Wrap a shop towel around the fuel rail service port.

    Click image to see an enlarged view

    Fig. Connect the CH-48027-3 to the fuel rail service port. Connect the CH-48027-2 to the CH-48027-3

  8.  
  9. Connect the CH-48027-3 (4) to the fuel rail service port.
  10.  
  11. Connect the CH-48027-2 (2) to the CH-48027-3 (4).
  12.  
  13. Place the hose on the CH-48027-2 (2) into an approved gasoline container.
  14.  
  15. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail.
  16.  
  17. Close the valve on the CH-48027-2 (2).
  18.  
  19. Remove the hose on the CH-48027-2 (2) from the approved gasoline container.
  20.  
  21. Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system:
    1. The fuel pipe connections.
    2.  
    3. The hose connections.
    4.  
    5. The areas surrounding the connections.
    6.  

  22.  
  23. Disconnect the CH-48027-2 (2) from the CH-48027-3 (4).
  24.  
  25. Disconnect the CH-48027-3 (4) from the fuel rail service port.
  26.  
  27. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
  28.  
  29. Install the fuel rail service port cap.
  30.  
  31. Install the engine cover, if required.
  32.  
  33. Tighten the fuel fill cap.
  34.  

 
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