Chevy Cobalt Detailed Fuel Pump Replacement in the Driveway

My car started leaking gas caused by what seems to be a factory defect that I was never notified about where the pump cracks at the stem. This situation might leave you in the driveway if you are lucky, in a non-op condition, but now the tank needs to be removed to swap the pump. This procedure can be done safely in the driveway as demonstrated.
After safely putting the car on drive on stands or jack stands and disconnecting the battery we begin by disconnecting the electrical connections and hose fittings as shown. I'm working alone so a small jack is used to assist in the supporting of the tank in this task as I loosen the tank straps. The jack gently lowers the tank as its still supported on the filler hose. Tube lowered, the filler tube is disconnected. The tank is dropped on the jack further and out of the car.
We can see the crack is evident, no doubt. Ill need to replace the pump. I don't feel good about the reviews about after market pumps so I'm going with the OEM AC Delco MU2220. The tank is completely cleaned before opening with a wash and scrub. I use brass to open the lock so it doesn't spark the lock ring. Cables disconnected the old pump negotiated out, the fuel is recovered from the tank with a siphon. The inside of the tank inspected and cleaned.
I take this time I opt to swap the fuel filter as well. Using tool OEM 25043 to detach the old filter, looking at the contents, it was ready. The replacement will be a Duralast FF4002DL.
With the arrival of the fuel pump I replace the O ring with the same sized one removed. I negotiate the pump back into place and set up the locking ring. Using a brass dowel and hammer I tap it into position its tapped it into place mindful of the H in the position mt the power connector.
I found it easier to remove the heat shield before tank re-installation by removing the two locking tabs. The driver side is installed first over the exhaust as shown, the jack supporting the passenger side. The filler hose should be brought over the cross-member. The heat shield is then negotiated around the exhaust and the tabs locked in. I did this alone, but two people helps. After a good inspection the jack is used to hold the tank up and the straps are reinstalled to hold the tank into position.
This is followed by the re-connection of all electrical and hose fittings, and refilling of at least 3 gallons of gas into the system. It took as expected several attempts to start the car to purge the air out of the system, though after that it ran normal. Going under and around to check for leaks letting it run for several minutes. The next test was to let it sit for several hours and restart to the car to see if it started right up, showing that there was no air introduced into the system.
#cobalt #chevycobalt

[@Daniel_deez_nutz]

I wish you uploaded earlier! This video is the best out there

[@retrotechandelectronics]

I appreciate that!

[@thesoulofmemories]

THE MOST PERFECTLY MADE VIDEO in this TOPIC. Guaranteed. Thank you sir for the high quality video and step by step directions. Very, very, well made indeed!

[@retrotechandelectronics]

You are very welcome

[@bigmwade1]

Excellent narrative and camera work... We appreciate all the little helpful hints and tips along the way... Great clean job... After this video... I'm definitely not intimidated by trying this myself.. Thank you sincerely bro

[@retrotechandelectronics]

Glad it was helpful!

[@googleuser868]

Top of the line video on this repair. None better I've viewed. Thanks much. Unusually clean underbody. Indiana road salt is working on ours but still cleaner than most. Gotta use the pressure washer underneath as best you can here.

[@eyeonart6865]

This is amazing instruction. You make me feel like I could do it. TY

[@iDavidWhite]

I am a 60 year professional, and you did really good

[@retrotechandelectronics]

Thank you.

[@ivancavalcanteusa]

Amazing way to teach unskilled d.i.y like myself thank you very much , you have another subscriber.

[@retrotechandelectronics]

Thanks and welcome

[@hans-joachimrumler9274]

Great Job. Your video will help me to fix our Cobalt. What I also like are the German messages of the board computer. Danke sehr.

[@retrotechandelectronics]

You are welcome!

[@ericevans9471]

No rust underneath. I love it

[@retrotechandelectronics]

Not a northern car

[@user-im1kt1nx1i]

Thanks for creating this video. I found it to be very helpful. I did get my car working again.

[@retrotechandelectronics]

You're welcome.

[@bottomofthemap696]

Thank you for the video, it helped me out!

[@retrotechandelectronics]

You're welcome!

[@javiercarrillo730]

Muchas Gracias por explicar tan bien la forma de cómo hacer el trabajo de remplazar la bomba y el filtro se lo agradezco mucho Mil Gracias por su valiosa información 😊👍🏼

[@retrotechandelectronics]

Encantada de ayudar

[@amike4211]

Well done! 5star install video. In my case in the coupes the metal fuel lines rot out on the driver side going up over the rear wheel. And I broke the 10mm bolt on the fuel filter. Slide the filter out don't bother touching the bolt 2 for 2 broke.

[@Dr.Grafenberg]

I just did the same 🤦‍♂️

[@googleuser868]

Same here. Twisted the end off the charcoal canister mounting bracket. Line broke into by the rusted through area by the wheel on removal. Got the full length factory line to replace. Unbelievably difficult path to fish that line through. Not much wiggle room. Considering cutting the new line and reassembling with compression fittings. Would be rust free new but hate to cut new lines on installation. If they made the line in sections and with flared fittings it would be much easier to install. An aftermarket company makes that very thing. Some have nylon flexible lines but won't fit in stock mounting brackets. I really wanted the OEM one piece line to work but on floor jacks it might be more trouble than it's worth.

[@frankperez7072]

Another great video. Much appreciated.

[@retrotechandelectronics]

Thanks.

[@gustavocamacho5873]

Nice Video, very good explaining and Help full 👍 ⭐️⭐️⭐️⭐️⭐️

[@retrotechandelectronics]

Glad it helped.

[@breckinmeyer7110]

Great video! I feel confident in doing this on my girlfriends SS now!

[@retrotechandelectronics]

Good luck!

[@jerryameral6760]

Excellent video and great usage of the repair manual

[@retrotechandelectronics]

Wasn’t the chitons manual.

[@theville3643]

@@retrotechandelectronics Haynes?🤔😁

[@retrotechandelectronics]

The 'Ville yup....

[@peterretsinas6225]

Good work!! Enjoyed watching the repair.

[@retrotechandelectronics]

Glad you enjoyed it. Thanks.

[@darthbubba866]

Time for a trip down to the Chevy dealer with the recall notice, old fuel pump, and new fuel pump receipt in hand. Your lawyer's business card stapled to the whole mess might help.

[@retrotechandelectronics]

And what would my time be worth for all of that effort to get back 200$

[@darthbubba866]

@@retrotechandelectronics You're right, you need to add your labor at whatever rate you charge for technical work, and fees for a rental car to drive to work while the Cobalt was out of commission due to their negligence. Seriously, time is money.

[@dustincampbell2581]

Excellent video helped me through the entire project.

[@retrotechandelectronics]

Glad it helped.

[@ryanamberger]

The first hose you remove at 1:33, does anyone know exact name or part number of that? I ran over a branch that shredded that tube badly. Need to replace, but having trouble determining for sure what to buy.

[@garyvanhoven9636]

having trouble getting one of the evap lines off. Any tips

[@ronlafountaner70]

I took the Best way to work on our Colbalt. Drive it to Chevy and let them go to town. To my surprise, These car are Very inexpensive to maintain. I had A problem with the Darn Engine light. Purge Valve Canister was Junk. I must say that these car's are great. Ps. Great Video.

[@retrotechandelectronics]

Thanks!

[@tommak6516]

Is that the valve next to the engine? What did that cost to replace? I think I may have the same problem. How old was the car and how many miles on your car when this happened?

[@75hdfxe]

Great job. Good thing you don't have a nosy HOA.

[@retrotechandelectronics]

It didn't look like too much going on with the car on ramps.

[@fishinfool247]

tip remove fuel line from fuel rail and put it in a gas can then remove fuel pump relay turn on the key and jump the two posts for the relay and the fuel pump will drain the tank into a can with no mess and fast

[@retrotechandelectronics]

Unless of course....... The fuel line is cracked...

[@z95m]

Chevrolet owes you some money.

[@retrotechandelectronics]

Good luck collecting on that.

[@davemiller7633]

What is the primary thing that made you change the fuel pump? Is there a specific code for it?

[@retrotechandelectronics]

The ends of the pump would crack and leak, it’s a know. Issue

[@davemiller7633]

@@retrotechandelectronics I see... So I've got a P0171 on my 2010 cobalt... But starts fine and doesn't stall.... No noise from fuel pump either... Probably not the pump then huh?

[@thegamingchef3304]

I had issues with my fuel filter leaking...Replaced it. Had issues with my Starter...Replaced it. Had issues with my Fuel pump, replaced it...Got a video also. Seems the cobalts didnt get good fuel system installation and parts upon being manufactured lol. I was wondering why my car had such poor mileage, I was thinking it was my old tires...But I kept smelling gas and it was getting stronger and stronger. Luckily it was just a fuel filter. But with this I'm glad there was no spark or nobody threw a cigarette out the window lol.

[@retrotechandelectronics]

and a crap ton of recalls, but only in some states, i didnt understand that.

[@tommak6516]

Was the filter itself leaking or was it leaking at connections? How old and how many miles on your car when this happened?

[@Idk7i]

great video. thanks for uploading it. i have the same issue.

[@retrotechandelectronics]

No problem 👍

[@aaroncohen7417]

Great video thanks!

[@retrotechandelectronics]

You're welcome!

[@germansolis4641]

I cuanto cuesta una bomba de gasolina de este carro

[@Daniel_deez_nutz]

I'm doing the same thing. How did you get around the exhaust tube? My shield under the gas tank is getting hung up on the exhaust tube

[@retrotechandelectronics]

The answer is in the video

[@Daniel_deez_nutz]

@@retrotechandelectronics turns out my Jack on the side was in the way. I didnt have blocks to put it up on

[@ClickClack_Bam]

@@Daniel_deez_nutz Same thing happened to me. I used another pump jack to raise the car up enough to move the jack stand outta the way & get the tank out & replace the jack stand.

[@Daniel_deez_nutz]

@@ClickClack_Bam yeah that's what I ended up doing too. I couldnt see that it was in the way while I was under there with the tank on me

[@midassnap9028]

What year was this car, do you know if it will be the same on a 2009?

[@retrotechandelectronics]

2008

[@midassnap9028]

@@retrotechandelectronics Thanks for the answer.

[@retrotechandelectronics]

@@midassnap9028 you’re welcome

[@johnanthonyaguirre3992]

Should this be the same process as the ss model ?

[@retrotechandelectronics]

It should be.

[@tonecapone0016]

I got the same problem. Only mine is a 2006. I will say the car has 135,000miles before the leak but this is unacceptable. GM has lost a life long consumer because they showed no remorse or consideration for me and my kids life!

[@retrotechandelectronics]

It was a poorly implemented recall

[@dainbaltierra8674]

Very Nice

[@retrotechandelectronics]

Thanks.

[@JoeyLovesTrains]

I haven’t seen to many Cobalt sedans with a manual transmission.

[@retrotechandelectronics]

This was one of the Cafe cars in 08. The one with the base options that got max economy to offset the Chevy trucks in the GM total average that year. Its rare indeed.

[@JoeyLovesTrains]

Retro Tech & Electronics one thing I find odd, is that the Pontiac G6 which (to my understanding) is supposed to be more luxurious than the Cobalt/G5 doesn’t come with a cabin air filter, or an external fuel filter (it’s built into the sending unit/fuel pump, idk what it’s called)

[@Dr.Grafenberg]

I think that car is missing an axle

[@retrotechandelectronics]

True FWD...

[@cjheitger4237]

Easy

[@antraciet]

Difficult job, looks easy on the video.

[@retrotechandelectronics]

The only difficult part was reinstalling the heat shield over the tank without a second person to support the passenger side of the tank.

[@googleuser868]

Looks easier to me once someone gifts you with a well made video tutorial. Takes the guesswork out of the equation. I've done these 3 times already on other vehicles and each is assembled different. Gets easier every time. Especially when a quality KZbin video like this shows exactly what to do and refreshes my memory. Worked on hundreds of cars over the decades and it's a constant learning process. Small challenges are fun when you're not in a hurry. Lol Old Chevy 350s were my favorite engine back in the 70s and 80s. Much easier to work on.

[@tommak6516]

Ha, Ha, Ha you sure are right about that.

[@cjheitger4237]

Bull shit it wouldn’t come off for me that east

[@googleuser868]

Take a break and try again. The right combination will seem effortless. Patience and finesse is better than a big hammer and high blood pressure. Many parts are fragile on vehicles today. Be gentle as possible. Works for me.

[@tommak6516]

@@googleuser868 I only have two tools, a real big hammer and an even bigger hammer.