Cavalier, Sunfire 2001-2005

Fuel Pump

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the fuel tank.
  6.  
  7. Remove or disconnect the following:


  8.  
  9. 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.



    Fuel sender assembly
     
    External fuel strainer
     
    Connector retainer from the wiring harness and the fuel pump
     

  10.  
  11. 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.
  12.  
  13. 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
     

  14.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the fuel sender assembly mounting to the tank



Click image to see an enlarged view

Fig. Exploded view of the fuel pump assembly

  1. Install or connect the following:
    NOTE
    Gently pull on the fuel pump reservoir to assure it is secure. If not secure, replace the entire fuel sender.



    Fuel pump outlet with a new seal by sliding it in the reservoir cover slots
     
    Fuel pump and baffle assembly onto the reservoir retainer by rotating it clockwise until seated
     
    Lower retainer assembly partially into the reservoir by aligning all 3 sleeve tabs and pressing the retainer onto the reservoir making sure all 3 tabs are firmly seated
     



    Connector retainer to the wiring harness and the fuel pump
     
    External fuel strainer
     
    Snapring, if equipped to the retainer slots while holding the modular fuel sender assembly down or use Fuel Sender Lock Nut Tool J-39765 in order to install the cam lock ring
     
    Fuel tank
     
    Negative battery cable
     

  2.  
  3. Pressurize the fuel system and verify no leaks.
  4.  

 
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