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HOMESERVICE MANUALSCHEVROLET2006COBALT SS, 4D SEDAN, STANDARDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 691 (ENGINE CONTROL SYSTEM & FUEL SYSTEM - 2.2L (L61) - INTRODUCTION (2 OF 2))REPAIR INSTRUCTIONSFUEL LEVEL SENSOR REPLACEMENT (RPO NU6)INSTALLATION 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 2008 Pontiac G5 and 2008 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: View of fuel level sensor
    GM1752283Courtesy of GENERAL MOTORS CORP.
  1. Position the fuel level sensor to the fuel pump module and slide the sensor down.
    2. Fig 2: View Of Fuel Pump Fuel Reservoir Pump Strainer Tabs
    GM1752264Courtesy of GENERAL MOTORS CORP.
  2. Ensure that the fuel level sensor retainer (2) is fully engages the fuel pump module.
    3. Fig 3: View Of Fuel Pump Flange Lock Ring, Flange & Seal
    GM1752259Courtesy of GENERAL MOTORS CORP.
  3. Position a NEW fuel pump flange seal (3) onto the fuel tank.
  4. If required, install the lock ring onto the flange. Position the fuel pump flange (2) and lock ring (1) over the fuel tank opening.
  5. Ensure that the fuel pump flange tab is aligned with the arrow on the fuel tank.
    6. Fig 4: View Of Fuel Sender Lock Ring
    GM1752256Courtesy of GENERAL MOTORS CORP.
  6. Connect the fuel tank vent valve and the fuel filter quick connect fittings (1) to the fuel pump flange. Refer to Plastic Collar Quick Connect Fitting Service .
  7. Connect the fuel level sensor electrical connector to the fuel pump flange.
  8. Slowly lower the fuel pump flange into the fuel tank.
  9. Using the J 45722  , lock the fuel sender lock ring.
  10. Install the fuel tank. Refer to Fuel Tank Replacement (RPO NU6)  or Fuel Tank Replacement (RPO NT7) .
RENDER: 1.0x

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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.