I would like to know how to remove and replace the fuel pump using detailed diagrams if possible.
Apr 4, 2010 at 9:39 AM
2004 Chevy Cavalier Fuel Pump
2004 CHEVROLET CAVALIER
HIBDON420
- MEMBER
- 1 POST
Advertisement
BLUELIGHTNIN6
- ✓ASE Certified Mechanic
- 16,542 POSTS
Relieve the fuel system pressure.
Drain the fuel tank.
Remove or disconnect the following:
Fuel sender assembly
External fuel strainer
Connector retainer from the wiring harness and the fuel pump
While holding the modular fuel sender assembly down, remove the snapring, if equipped or if equipped with a cam lock ring use Fuel Sender Lock Nut Tool J-39765 to press down and rotate the cam lock ring to remove it.
WARNING
If the modular fuel sender assembly is retained by a snapring, it may spring up from its position. When removing the modular fuel sender from the tank, be aware that the reservoir bucket is full of fuel. It must be tipped slightly during removal to avoid damage to the float.
Gently release the tabs on the sides of the fuel sender at the cover assembly. Begin by squeezing the sides of the reservoir and releasing the tab opposite the fuel level sensor. Move clockwise to release the second and third tab in the same manner.
Remove or disconnect the following:
Fuel pump electrical connection by lifting the cover assembly
Baffle and pump assembly from the retainer by rotating the fuel pump baffle counterclockwise
Fuel pump outlet by sliding it out of slot
Fuel pump outlet seal
Drain the fuel tank.
Remove or disconnect the following:
Fuel sender assembly
External fuel strainer
Connector retainer from the wiring harness and the fuel pump
While holding the modular fuel sender assembly down, remove the snapring, if equipped or if equipped with a cam lock ring use Fuel Sender Lock Nut Tool J-39765 to press down and rotate the cam lock ring to remove it.
WARNING
If the modular fuel sender assembly is retained by a snapring, it may spring up from its position. When removing the modular fuel sender from the tank, be aware that the reservoir bucket is full of fuel. It must be tipped slightly during removal to avoid damage to the float.
Gently release the tabs on the sides of the fuel sender at the cover assembly. Begin by squeezing the sides of the reservoir and releasing the tab opposite the fuel level sensor. Move clockwise to release the second and third tab in the same manner.
Remove or disconnect the following:
Fuel pump electrical connection by lifting the cover assembly
Baffle and pump assembly from the retainer by rotating the fuel pump baffle counterclockwise
Fuel pump outlet by sliding it out of slot
Fuel pump outlet seal
Apr 4, 2010 at 11:18 PM
Repair Safety Notice: This information is for general instructional purposes only. Vehicle repair can be dangerous. Verify all information, follow manufacturer service procedures, use proper tools and safety equipment, and consult a qualified repair shop when needed.