Replacing The Fuel Pump In Your '09 Cobalt: Step-By-Step Guide

If you're experiencing issues with your 2009 Cobalt's fuel pump, you may need to replace it. The fuel pump is located inside the fuel tank and can be accessed by removing the fuel tank or through an access panel in the passenger compartment. Before attempting any repairs, it is important to diagnose the fuel pump to ensure it is faulty. This can be done by checking if power is getting to the pump and ensuring that the issue is not caused by a bad relay, fuse, or circuit. If you decide to replace the fuel pump, there are a few steps you need to follow. First, drain the fuel from the tank and remove the filler neck hose at the fuel neck. Then, support the tank and remove the tank support straps and insulator strips. Next, lower the fuel tank enough to access the fuel and electrical connections, and disconnect them. Finally, remove the fuel sender assembly and seal ring, and install the new fuel pump. It is recommended to refer to a repair manual or seek assistance from a qualified mechanic if you are unsure about any of the steps.

Removing the fuel tank

To remove the fuel tank from a 2009 Chevrolet Cobalt, you will first need to drain the fuel tank. Next, raise the vehicle and safely support it, ensuring it is high enough for you to work underneath. Loosen the fuel neck hose at the fuel neck and disconnect the filler neck from the tank. Support the tank and remove the tank support straps and insulator strips. Remove the frame-mounted bracket and lower the fuel tank shield. Now, lower the fuel tank enough to access the fuel and electrical connections. Disconnect the fuel feed and vapor hoses, as well as the electrical connectors. Finally, remove the fuel sender assembly and seal ring.

It is important to note that you should always ensure power is getting to the pump and diagnose any issues with the fuel pump before removing the fuel tank. This can save you time and effort in case the issue is a bad relay, bad fuse, or bad circuit.

Checking for power to the pump

To check for power to the fuel pump of a 2009 Cobalt, you can start by checking the fuel pump fuse. Locate the fuse box, which you can find with the help of your owner's manual, and find the fuse that corresponds to the fuel pump. If it is blown, it will be broken or burned. If it looks good, check the rest of the fuses related to the fuel system. If no fuses are blown, listen for the fuel pump relay clicking on when you turn the key.

If you need to replace a fuse, make sure to use one with the proper amp rating. Do not install one with more amps than necessary. If you find a blown fuse, this could be a sign of a high amp draw, which means you should check the individual circuits. Try to replace the blown fuel fuse and attempt to start the vehicle. If the fuse blows again, a direct short is present and you will need to take your car to a shop to get it checked out.

You can also check the voltage at the pump itself. Check your vehicle's service manual to find out where to check and the proper procedure for checking it. Perform a source voltage test to determine whether the charge that's leaving the fuse is getting to the pump. If no power is making it to the fuel pump, then check the fuel pump relay circuit, as you could have a bad relay.

Perform a drop test using a voltmeter. Check to make sure that the power wire shows the full voltage and the grounding wire shows that it's grounded properly. If this electrical test reveals nothing, it's likely that your fuel pump is the problem and it will need to be replaced. However, you can check more thoroughly by completing a fuel pressure test.

Identifying the correct replacement pump

To identify the correct replacement fuel pump for your 09 Colbalt, you will need to refer to your owner's manual or a vehicle-specific repair manual. The make and model of your car will determine the type of fuel pump it requires.

There are two main types of fuel pumps: mechanical and electronic. Mechanical fuel pumps were once standard, sometimes attached outside the fuel tank, but they have been replaced by electronic fuel pumps in modern cars. Electronic fuel pumps are generally mounted inside the fuel tank and use a direct-current (DC) electric motor to draw fuel from the tank.

When identifying the correct replacement pump, you will also need to consider the specific characteristics of your vehicle, such as the engine size and type, as well as the age and geographic region of your car. It is important to refer to a trusted source, such as a certified mechanic or dealership, to ensure you are purchasing the correct fuel pump for your vehicle.

Additionally, you may want to consider the cost of the replacement pump and the labour required for the installation. The cost of a fuel pump replacement can vary depending on these factors, but it typically ranges from $600 to $1300.

By taking these factors into account and consulting the appropriate resources, you can identify the correct replacement fuel pump for your 09 Colbalt.

Disconnecting fuel and electrical connections

Disconnecting the fuel and electrical connections is a crucial step in replacing the fuel pump in a 2009 Chevy Cobalt. Here's a detailed guide on how to approach this task:

Firstly, ensure that you have identified the correct fuel pump for your vehicle. The 2008 Chevy Cobalt, for instance, has a different fuel system from the standard model, as it is a Partial Zero-Emissions Vehicle (PZEV). The PZEV model does not have an external filter or the typical module, so keep that in mind when sourcing parts.

Now, onto the steps for disconnecting the fuel and electrical connections:

• Drain the fuel tank: Before beginning any work, it is important to drain as much fuel as possible from the tank to reduce the risk of spillage during the removal process.
• Secure the vehicle: Raise and safely support your Chevy Cobalt. This will provide you with adequate access to the underside of the vehicle and the fuel tank.
• Loosen and disconnect: Loosen the fuel neck hose at the fuel neck and disconnect the filler neck from the tank.
• Support and remove the fuel tank: Lower the fuel tank enough to access the fuel and electrical connections. Disconnect the fuel feed and vapor hoses, as well as the electrical connectors.
• Remove the fuel pump assembly: Depending on your vehicle's configuration, you may need to twist a ring or unscrew bolts to remove the fuel pump assembly from the fuel tank. This step may require working in a cramped space, so have a good light source and appropriate tools within easy reach.
• Label and set aside components: As you remove parts, it is crucial to label and set them aside in an organised manner. This will make it easier when it comes time to reinstall the new fuel pump and associated components.

By following these steps, you will have successfully disconnected the fuel and electrical connections, ready for the installation of a new fuel pump. Remember to exercise caution when working with fuel systems and always refer to a qualified mechanic if you are unsure about any aspect of the procedure.

Replacing the fuel tank

To replace the fuel tank on a 2009 Cobalt, you will first need to remove the fuel tank. This is not too difficult a job, but there are a few important steps to follow.

Firstly, diagnose the fuel pump to ensure it needs replacing. Check for a bad relay, bad fuse, or bad circuit. You can do this by powering the pump externally to ensure it has failed before removing the fuel tank.

Next, drain the fuel from the tank as much as possible. Then, raise and safely support the vehicle, ensuring it is high enough for you to work under. Loosen the fuel neck hose at the fuel neck and disconnect the filler neck from the tank. Support the tank and remove the tank support straps and insulator strips. Remove the frame-mounted bracket, and lower the fuel tank shield.

Now you can lower the fuel tank enough to access the fuel and electrical connections. Disconnect the fuel feed and vapor hoses, and then disconnect the electrical connectors.

At this point, you can remove the fuel sender assembly and seal ring. Install a new seal ring and sender, and then raise the tank enough to connect the fuel feed/vapor hoses and electrical connectors. Raise the tank fully and install the fuel tank shield. Connect the fuel tank filler neck and tighten the clamp.

Finally, install the fuel tank brackets and insulator strips, torque nuts to 115 in-lbs. Install the fuel tank filler cap and connect the battery negative cable.

You can now turn the ignition switch off and on to check for leaks.

Note: It is recommended that you take your vehicle to a qualified mechanic or dealership to perform this job if you are unsure about any of the steps or procedures.

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