Sylvie Willis
If you have a 2009 Chevy Cobalt with a leaky fuel return line, there are a few options for repair. You could replace the whole line, which costs around $200, or you could try to patch it with a few feet of rubber fuel line, which is a cheaper option. There are also fuel line kits available that are resistant to rust, dry rot, and cracking, and are suitable for both gas and diesel engines. These kits are easy to install and can be bent to fit your vehicle's unique needs.
| Characteristics | Values |
|---|---|
| Repair method | Replace the whole line or the o-ring in the joint |
| Cost of replacement line | $200 |
| Cost of nylon line kit | $100 |
| Difficulty | Cutting the old line out and fitting the heat shield material back in is the hardest part |
| Fuel line material | Steel or rubber |
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$45.88
What You'll Learn
Replacing the whole line
If you need to replace the whole fuel return line on a 2009 Chevy Cobalt, you have a few options. The first is to replace the line with a new steel line, which is more expensive but may be more durable. The second option is to patch in a few feet of rubber fuel line, which is cheaper but may not last as long.
If you choose to replace the whole line with a new steel line, you can purchase a fuel line kit that includes all the necessary clips and fasteners. Simply remove the factory clips and use the supplied steel clips and fasteners to secure the fuel hose at all the factory clamp locations. Make sure to shape the line to fit your vehicle's unique needs.
If you choose to patch in a few feet of rubber fuel line, you will need to cut out the old line and fit the new line in its place. This option may be more difficult to install, as you will need to fight with the hard lines to get them installed.
Additionally, if one of the plastic nipples on the fuel pump assembly is cracked or broken, it will need to be replaced. This may involve replacing the o-ring or the plug at the beginning of the line from the tank.
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Replacing the o-ring in the joint
If you need to replace the o-ring in the joint of your 09 Chevy Cobalt fuel return line, the first step is to locate the leak. Once you have done this, you can replace the o-ring. This is a cheaper option than replacing the whole line, which costs $200.
To replace the o-ring, you will need to cut out the old line and fit a new one. You can buy a fuel line kit to help with this, which is resistant to rust, dry rot, and cracking, and is suitable for both gas and diesel engines. These kits are easy to bend, so you can shape them to fit your vehicle's unique needs. Alternatively, you can patch in a few feet of rubber fuel line, which is a cheaper option.
When cutting out the old line, be aware that the hardest part is fitting the heat shield material back in and wiring it in place. You will also need to remove the factory clips and use the supplied steel clips and fasteners to secure the fuel hose at all the factory clamp locations.
If one of the plastic nipples on the fuel pump assembly is cracked or broken, it will also need to be replaced.
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Using a fuel line kit
To install a fuel line kit, simply remove the factory clips and use the supplied steel clips and fasteners to secure the fuel hose at all the factory clamp locations. The fuel line kit is easy to bend, so you can shape it to fit your vehicle's unique needs.
One example of a fuel line kit is the one offered by Inline Tube, which comes with a new filter and appropriate fittings already attached. The kit costs about $100 and can replace about 12 feet of old line.
Another option is the fuel line kit offered by Amazon, which is designed to fit Chevrolet Cobalt 05-10 models. This kit is also easy to install and is resistant to rust, dry rot, and cracking. It is also suitable for both gas and diesel engines.
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Patching in a few feet of rubber fuel line
If you're looking to patch in a few feet of rubber fuel line to your 09 Chevy Cobalt, it's likely that you have a leaky return line. The first step is to identify the source of the leak. Once you've done that, you can decide whether to replace the whole line or just the o-ring in the joint. If you're on a tight budget, it might be more cost-effective to patch the line with rubber fuel line rather than replacing the entire run of steel.
To do this, you'll need to remove the factory clips and use steel clips and fasteners to secure the fuel hose at the factory clamp locations. Make sure the fuel line kit you purchase is easy to bend so you can shape it to fit your vehicle. Avoid using nylon hose, as it can easily crush when making tight bends, potentially causing fuel starvation.
When replacing the fuel line, the hardest part will be cutting the old line out and fitting the heat shield material back in and wiring it in place. You can purchase a fuel line kit that includes a new filter and appropriate fittings already attached, making the process easier.
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Replacing a plastic nipple on the fuel pump assembly
If one of the plastic nipples on the fuel pump assembly is cracked or broken, it will have to be replaced. This can be done by purchasing a fuel line kit, which is available in both steel and rubber. The kit will come with a new filter and appropriate fittings already attached, and cost about $100.
To install the kit, simply remove the factory clips and use the supplied steel clips and fasteners to secure the fuel hose at all the factory clamp locations. The hardest part of the process is cutting the old line out, and fitting the heat shield material back in and wiring it in place.
It is important to note that the original hard steel lines and rubber hose are susceptible to rust, dry rot, and cracking, so it is recommended to replace them with a more durable option. Quick-fix fuel line kits are easy to bend, so you can shape them to fit your vehicle's unique needs.
If you are unable to replace the entire line, you can try to pinpoint the exact location of the leak and replace just the o-ring in the joint. This is a more affordable option, as the o-ring is not expensive.
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Frequently asked questions
The cost of replacing the fuel return line in a 2009 Chevy Cobalt can vary depending on the materials used and the extent of the repair. Some people have reported spending around $100 on a nylon line kit from Inline Tube, while others have spent up to $200 on a complete steel line replacement.
If you notice any leaks or corrosion on the fuel return line, it is likely that it needs to be replaced. Leaks can be identified by looking for any signs of fuel dripping or pooling under the car. Corrosion can appear as a white, flaky substance on the metal surfaces of the fuel line.
It is possible to repair or replace the fuel return line yourself, but it is important to have some basic knowledge of car mechanics and access to the appropriate tools. There are several online forums and resources that can provide guidance on how to perform this repair.
Fuel line kits, such as the one mentioned in the Amazon listing, offer several benefits over traditional steel lines and rubber hoses. They are resistant to rust, dry rot, and cracking, and can be easily bent to fit the unique needs of your vehicle. Additionally, fuel line kits typically come with all the necessary clips and fasteners for a quick and secure installation.
