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 165 (ENGINE CONTROLS - 2.2L (L61) INTRODUCTION)REPAIR INSTRUCTIONSFUEL TANK MODULE REPLACEMENT - SECONDARYINSTALLATION 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 Vue. However, it is still accessible from the selected car via links, so may be relevant.
- If the fuel level sending unit is being replaced, install the fuel level sending unit into the new fuel pump. Refer to Fuel Level Sensor Replacement - Secondary .
- Connect the suction port (1).
- Insert the new secondary fuel pump module with the level sender and new fuel pump-to-tank seal. Ensure the orientation tabs are aligned.
- Use the SA9156E to install the fuel pump lock ring. See Special Tools .
- Connect the EVAP line quick connect.
- Install the fuel tank. Refer to Fuel Tank Replacement .
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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.