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MikeB85, ASE Certified Technician
Category: Chevy
Satisfied Customers: 354
Experience:  ASE Certified, I-Car Trained and Certified, Automotive Technology Degree
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How to replace fuel pump on 2001 chevy cavalier

Resolved Question:

how to replace fuel pump on 2001 chevy cavalier
Submitted: 9 years ago.
Category: Chevy
Expert:  MikeB85 replied 9 years ago.

Hi there,

Here is the procedure for replacing the fuel pump. To do this you will have to lower the fuel tank in order to access the pump. Here is the procedure:

Fuel Sender Assembly Replacement

Tools Required

J 39765 Fuel Sender Lock Nut Wrench

Removal Procedure

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.

    Object Number: 14057  Size: SH

  1. Remove the fuel tank (4).
  2. Disconnect the wiring harness from the fuel sender and the fuel tank pressure (FTP) sensor.
  3. 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.

  4. Use the J 39765 in order to press down and rotate the retaining ring (1).
  5. Remove the fuel sender assembly.

Installation Procedure

    Object Number: 14057  Size: SH

  1. Install the new seal on the fuel tank (4).
  2. Align the fuel pipes parallel with the mark on the fuel tank.
  3. Slowly apply pressure to the top of the spring loaded sender until the sender aligns flush with the retainer on tank.

    Important: Ensure that the retaining ring is fully seated within the tab slots.

  4. Install the retaining ring
  5. Connect the wiring harness to the fuel sender and the FTP sensor.
  6. Install the fuel tank.

Fuel Tank Replacement

Removal Procedure

  1. Relieve the fuel system pressure.
  2. Drain the fuel tank.
  3. Raise the vehicle.
    Object Number: 54520  Size: SH

  4. Disconnect the quick-connect fitting at the fuel filter.
  5. Disconnect the fuel return pipe quick connect fitting.
  6. Remove the rubber exhaust hangers. Allow the exhaust system to rest on the rear axle.
  7. Remove the exhaust heat shield.
  8. Loosen the fuel filler hose clamp at the fuel tank.
  9. Disconnect the fuel filler hose from the fuel tank.
  10. Disconnect the evaporative emission (EVAP) vapor pipe from the EVAP canister.
  11. Disconnect the electrical harness from the multi-way rear body connector and fuel strap.
    Object Number: 49897  Size: SH

  12. With the aid of an assistant, support the fuel tank (1).
  13. Disconnect the fuel tank retaining straps.
  14. Lower the fuel tank.
  15. Remove the fuel sender assembly from the tank.

    Installation Procedure

    Object Number: 49897  Size: SH

  1. Install the fuel sender assembly to the fuel tank.
  2. With the aid of an assistant, raise the fuel tank (1) to the vehicle.
  3. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  4. Install the fuel tank retaining straps.

    Tighten the strap bolts to 35 N·m (26 lb ft).

  5. Connect the wiring harness into the multi-way rear body connector.
  6. Connect the EVAP vapor pipe to the EVAP canister.
  7. Connect the fuel filler hose to the fuel tank.

    Tighten the fuel filler hose clamp to 3 N·m (27 lb in).

  8. Install the rubber exhaust hangers.
  9. Install the exhaust heat shield.

    Tighten the exhaust shield bolt to 2 N·m(18 lb in).

    Tighten the exhaust shield nuts to 1 N·m(9 lb in).

  10. Connect the fuel return pipe and fuel filter quick-connect fittings.
  11. Lower the vehicle.
  12. Refill the fuel tank.
  13. Install the fuel filler cap.
  14. Connect the negative battery cable.
  15. Inspect for fuel leaks:
    14.1. Turn ON the ignition for 2 seconds.
    14.2. Turn OFF the ignition for 10 seconds.
    14.3. Turn ON the ignition.
    14.4. Inspect for fuel leaks.
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