Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 12 (ENGINE CONTROLS - INTRODUCTION)REPAIR INSTRUCTIONSFUEL LEVEL SENSOR REPLACEMENTINSTALLATION PROCEDURE
2006 Chevrolet Cobalt SS, 4D Sedan, Standard
Installation Procedure
2006 Chevrolet Cobalt SS, 4D Sedan, StandardSECTION Installation Procedure
WARNING: This page is about a different car, the 2005 Saturn L300. However, it is still accessible from the selected car via links, so may be relevant.
- Slide the new sender unit into place until a click is heard, pulling up lightly to ensure the sender unit is locked into place.
- Connect the electrical connections.
- Install the pump module and lock ring using a new tank seal.
- Reconnect the fuel lines and electrical connectors to the fuel pump.
- Install the fuel tank. Refer to Fuel Tank Replacement .
IMPORTANT:
Verify that the float arm on the sender unit maintains the correct relationship to the pump module by standing the module on a flat, horizontal surface. The float should lay on the surface.
IMPORTANT:
The fuel pump module to tank seal must always be replaced whenever the module is removed from the fuel tank.
RENDER: 1.0x
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.