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roadsidejerry, auto mechanic
Category: Chevy
Satisfied Customers: 2948
Experience:  Auto Mechanic 39 years, 30 with NYPD Fleet Service Division
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Installation instructions for 2003 cavalier fuel pump

Resolved Question:

Installation instructions for 2003 cavalier fuel pump?
Submitted: 8 years ago.
Category: Chevy
Expert:  roadsidejerry replied 8 years ago.

Hi,you need to remove the fuel tank,I am sending the instructions for replacing the fuel pump,if you need the instructions for removing the fuel tank let me know.



J 39765 Fuel Sender Lock Nut Wrench


CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel sender assembly.


  1. Remove the fuel tank (4).
  2. Disconnect the wiring harness from the fuel sender and the fuel tank pressure (FTP) sensor.
  3. Use the J 39765 in order to press down and rotate the retaining ring (1). IMPORTANT:
    • The modular fuel sender assembly may spring up.
    • When removing the modular fuel sender assembly from the fuel tank, be aware that the 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.
  1. Remove the fuel sender assembly.
  2. Remove the fuel level sensor from the fuel sender assembly.



  1. Install the fuel level sensor to the fuel sender assembly.
  2. Install the new seal on the fuel tank (4).
  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 J 39765. IMPORTANT: Be sure that the retaining ring is fully seated within the tab slots.
  6. Connect the wiring harness to the fuel sender and the FTP sensor.
  7. Install the fuel tank.
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