Replace a fuel pump on a Cavalier

REMOVAL & INSTALLATION -2003 Chevrolet Cavalier
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WARNING: To reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender assembly gasket when reinstalling the fuel sender assembly.
NOTE: Fuel level sensor and fuel tank pressure sensor are removed as an assembly with the fuel sender assembly which also includes the fuel pump and fuel strainer. When installing fuel sender assembly, DO NOT fold or twist strainer. This will restrict fuel flow.
NOTE: Numbers in parenthesis correspond to numbered components in referenced illustration.

FUEL SENDER ASSEMBLY
Removal
Fuel sender assembly is located in the fuel tank. See Fig. 77 .
1.Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE (GASOLINE) . 2.Remove fuel tank. See FUEL TANK (GASOLINE) .
CAUTION:The fuel sender assembly may spring up when removing. The fuel sender assembly reservoir bucket is full of fuel. The reservoir must be tipped slightly during removal to avoid damage to the float. Carefully discard the reservoir fuel into an approved container.
3.Use the Fuel Sender Lock Nut Wrench (J 39765) to press down and rotate the retaining ring (1). 4.Remove the fuel sender assembly. 5.Remove the fuel level sensor from the fuel sender assembly. See FUEL LEVEL SENSOR .
Fig. 77: Locating Fuel Sender Assembly Courtesy of GENERAL MOTORS CORP.
Installation
1.Install the fuel level sensor to the fuel sender assembly. See FUEL LEVEL SENSOR . 2.Install the new seal on the fuel tank (4). See Fig. 77 . 3.Align the fuel pipes parallel with the mark on the fuel tank. 4.Slowly apply pressure to the top of the spring loaded sender until the sender aligns flush with the retainer on tank. 5.Install the retaining ring (1) using the fuel sender lock nut wrench. 6.Connect the wiring harness to the fuel sender and the FTP sensor. 7.Install the fuel tank. See FUEL TANK (GASOLINE) .

7/31/2008
REMOVAL & INSTALLATION -2003 Chevrolet Cavalier
Page 2 of 2

7/31/2008