Question about 1996 Chevrolet Cavalier

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We THINK it's the fuel pump on my 2005 chevy cavalier. Any ideas on how to get startd on this project?

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  • sheila643 Apr 20, 2009

    Thank you so much! Yes, relay and fuses have been checked. SO frustrating! After reading things online LOT'S of cavalier owners have had this same problem. Fuel pump with the dealership is $426 and labor they are wanting to charge $496 - that's why we are wanting to fix this on our own! Thanks again!~

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  • Chevrolet Master
  • 599 Answers

The fuel pump is located in the gas tank itself, diconnect all lines and electrical connectors lower tank and remove the lock ring holding the fuel sending unit replace pump. this is not a job for the faint of heart, be careful, no sparks, do not run the pump unless it is in the gas tank sealed.good luck. before i did this i would test for fuel pressure, get back to me if you need more help,please rate my fix as i strive for the best, Ray

Posted on Apr 20, 2009

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  • Chevrolet Master
  • 6,982 Answers

First, verify that the fuel pump is actually bad. check relay, fuse etc. If you have done that and are satisfied with your diagnosis, and have also replaced the filter, If you can drive it, let the fuel level go as far down as possible (gasoline is heavy, the least in the tank the better). Spray the bolts that hold the tank in the day before you do the work, and again before you begin, with wd40 or other good solvent. It's easier to do this work using a decent floor jack with a piece of plywood on it to avoid damaging tank but two people can do it without much problem. Pay attention to where hoses go and make sure you have the tool to remove fittings. If you have never done this kind of job before, it helps to have a manual such as haynes, to guide you through it. (instructions not too complicated but too long to re-write here. Be sure you don't use droplights, any electrical items or cigarettes etc near where you are working...vapors can travel some distance along the ground. After the tank is down, empty remainder of fuel and clean out inside. Have containers to store fuel ready before you begin job.
Good luck with your project!!!

Posted on Apr 20, 2009

  • Richard Scordino Apr 20, 2009

    Glad to help...any problems along the way, just ask!!!

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