I bought our 2006 Cobalt LT new for my wife, in June of 06. The warranty expired 4,000 miles ago, and we now have a small fuel leak in the area of the fuel tank.
I have not dropped the fuel tank as of yet, but it appears the leak is located at or near the fuel pump hat, the leak is not bad, it is more like seeping.
Has anyone had the privledge of dealing with this problem?
I hope that I dont have to replace the fuel pump, but if it is required, will I need any special tools to remove the fuel lines?

 

I also had a fuel odor in my ’07 Cobalt about the same time I was experiencing an extended engine crank cycle after sitting all night. I saw a slight fuel residue on the bottom of the gas tank and after lowering the tank I found one of the fuel lines coming out of the tank was cracked and weeping fuel. While removing the fuel pump both of the lines snapped right off. Way too brittle but a new pump and sending unit (all one assembily) fixed it right up with minimal difficulty for about $250. I found the cheapest OEM part at this site: http://www.trademotion.com

Basic hand tools and a friend are all you need to lower and replace the tank. I recommend replacing the fuel filter and you will require a fuel line disconnect tool for that effort.

1. Determine which fuel pump your Cobalt will need. It will have one of the following engines: 2.0 L S/C LSJI4, 2.0 L Turbo LNFI4, 2.2 L L61I4, 2.2 L LAPI4 or 2.4 L LE5I4.

2. Disconnect the battery. Remove the fuel tank, and release the retaining tab on the fuel tank retainer. Release the electrical harness for the fuel tank from the retaining slot and disconnect the harness from the fuel tank pressure sensor.

3. Release the fuel pump retaining lock ring by carefully rotating it. Slide the ring over the fuel pump pipes and slowly raise the fuel pump until you can just see the float arm for the fuel level sensor. Empty the fuel in the pump reservoir into a container and remove the fuel pump.

4. Install the new fuel pump using the items included in the kit, especially the tank seal. Tilt the pump towards the back of the fuel tank to avoid bending the fuel level sensor float arm.

5. Replace the fuel filter.

6. Install the fuel tank with the aid of an assistant as you tighten the fuel tank strap bolts to 18 ft. lbs with a torque wrench. Tighten the fuel filler hose to 40 in. lbs. with a torque wrench.

7. Reconnect battery.

8. Expect extended cranking time on initial start-up until fuel system is pressurized by new pump.

Good Luck