Filler Tube Replacement for Chevrolet Cobalt 2007

Caution: Refer to Gasoline/Gasoline Vapors Caution in the Preface section.

1. Remove the fuel fill cap.
2. Drain the fuel tank. Refer to Fuel Tank Draining .
3. Remove the fuel fill pocket. Refer to Fuel Tank Filler Pipe Housing Replacement .
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
5. Disconnect the fuel fill vent pipe quick connect fitting (1) from the evaporative emission (EVAP) canister. Refer to Plastic Collar Quick Connect Fitting Service .
6. Cap or plug the EVAP canister fitting in order to prevent system contamination.



7. Remove the fuel fill pipe lower bolt.



8. Disconnect the fuel tank vent line quick connect fitting (2) from the fill pipe recirculation line. Refer to Plastic Collar Quick Connect Fitting Service .
9. Loosen the fuel fill hose clamp (3) at the fuel tank.
10. Remove the fuel fill hose from the fuel tank.
11. Cap or plug the fuel tank opening and vent line in order to prevent fuel loss and/or system contamination.
12. Remove the fuel fill hose/pipe.

1. Remove the caps or plugs from the fuel tank opening and vent line.
2. Install the fuel fill hose to the fuel tank. Align the "D" notch on the fill hose (1) with the "D" notch on the fuel tank (1).

Notice: Refer to Fastener Notice in the Preface section.

3. Tighten the fuel fill hose clamp (3) at the fuel tank.

Tighten
Tighten the clamp to 4.5 N·m (40 lb in).

4. Connect the fuel tank vent line quick connect fitting (2) to the fill pipe recirculation line. Refer to Plastic Collar Quick Connect Fitting Service .



5. Install the fuel fill pipe lower bolt.

Tighten
Tighten the bolt to 10 N·m (89 lb in).




6. Remove the cap or plug from the EVAP canister fitting.
7. Connect the fuel fill vent pipe quick connect fitting (1) to the EVAP canister. Refer to Plastic Collar Quick Connect Fitting Service .
8. Lower the vehicle.
9. Install the fuel fill pocket. Refer to Fuel Tank Filler Pipe Housing Replacement .
10. Refill the fuel tank.