08 Cobalt - Fuel Tank and Fuel Filler neck

Описание: Brother Kevin 2008 Chevy Cobalt has a new problem.
While driving home he smelled some burning plastic so pulled over at the fuel station/truck stop and found the fuel tank strap had broken and the plastic tank fell onto the hot exhaust pipe, melting the tank and leaking fuel. HE GOT VERY LUCKY THE CAR DID NOT CATCH FIRE!

He did pretty good job with a temporary repair to make it home. (THIS IS DANGEROUSE AND VERY HIGH RISK of fire, explosion, injury and death) do not attempt what Brother Kevin did. He is a highly skilled Mongo, just like Mongo. Now that Brother Kevin home time to get this whole fuel tank, and straps and maybe more fixed.

First step is to check your RPO codes to make sure you get the correct parts for your cobalt. For a cobalt the codes are in the trunk on the driver side.
This one is RPO codes - NE1 NU6 (Communist State of California, CSC emissions)
Mongo get a great deal on a fuel tank from the junk yard. No fuel pump.
If you want to replace the Fuel tank, Fuel Filler neck, or Fuel pump then THIS IS THE BEST VIDEO for you!

Fuel tanks are easy to remove in theory. Disconnect the fuel lines, Disconnect the electrical connectors, Disconnect the Fuel fill neck and vent line, remove the tank straps and the tanks comes down/out. In a cobalt the exhaust system should be removed but it so old and rusty that it may break so we opt to not remove it, so it coming down at an angle. KEEP AN EYE ON EVERYTHING. You may not be able to get to some parts until the tank start to lower down. In this example the fuel line connections are not accessible until the tank is lowered. Only then can the tank lock ring be removed to open the cover and the tank line connections are just underneath. GM really messed this one up.

00:00 HIs STORY
02:46 Remove fuel tank
Disconnect the fuel fill neck, remove the fuel tank straps (be sure to support the tank before removing the straps), disconnect the fuel pump electrical bulkhead connector, Disconnect the EVAP/vent hoses. Lower fuel tank to gain access to the locking ring. Use a flat head/chisel/punch and a hammer to remove the lock ring from the tank. Disconnect the 2 fuel lines and 2 electrical connectors.
06:57 Drain fuel and swap the insides
Couple different way to syphon the fuel out of a tank, pick your favorite. The Fuel pump , filters and other inside parts need to be swapped into the new/used/junk yard tank. The pump and large black part need to be turned to the left then pull out.
08:56 Reinstall ALL
Basically reverse order to install. Make sure the Fuel tank O-ring is installed correctly before closing the tank. Also make sure all electrical and fuel lines are connected inside before closing the tank. Be sure the indent on the cover is aligned with the arrow on the tank.
Brother Kevin updated the fuel straps to some nice stainless steel. Also made a makeshift heatshield to protect the new tank, so IF the tank falls again it won't melt the tank...hopefully
11:12 FUEL LEAK
Found some holes in the fuel filler neck by the rubber hose. Needed to order a new one.
11:53 Fuel Filler neck removal
T30 torques bits on the fuel cap area. Remove the hose clamp for the Fuel filler neck and the vent hose. 10mm bolt on the fuel filler neck bracket. Easier to work on by removing the pass side rear wheel, 19mm for the lug nuts. Then remove the inner wheel well liner, couple plastic push pins and 1, 10mm nut.
13:44 Install new fuel filler neck
Noticed the new part doesn't match the old part soo...
Its missing a bend, and about 6 inches short - THATS WHAT SHE SAID!!!
Brother Kevin say F^^^ it we not waiting to return and get right one, we run what we brung. So decide to use part of an upper radiator hose from an 04 Silverado to make up the difference. Pour some fuel in and no leaks so far.
Mongo not sure how well this will work so stay tuned to mongo fix and he keep you posted. NO IDEA if this is a good idea or a bad idea - Leave comment with what you think.

Hopefully this video helps you if you want/need to replace the fuel tank and or fuel filler neck in your 2008 cobalt.
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