How to Replace the Fuel Pump on a 1997 Cavalier

Fuel delivery problems -- including inadequate acceleration, uneven idle, or engine stalls -- can be caused by a failing fuel pump. After first diagnosing the problem, a failing fuel pump can be replaced in a 1997 Chevrolet Cavalier by most backyard mechanics with the aid of an assistant to raise and lower the fuel tank. The task does include many steps for completion, but it can be completed in a few hours time.

Things You'll Need

• Jack stands
• Automotive jack
• Fuel line disconnect tool
• Screwdriver
• Socket set
• Snap-ring pliers

Instructions

1. Relieve the fuel system pressure. Remove the fuel filler neck cap and disconnect the fuel pump electrical connector near the fuel tank. Start the vehicle and run it until the fuel runs out and the engine stalls.

2. Lift the rear of the vehicle with an automotive jack and support it with jack stands.

3. Remove the rubber exhaust hangers and allow the rear of the exhaust to hang down, allowing access to the fuel tank.

4. Remove the fuel filler hose and vapor return hose clamps with a screwdriver and disconnect the hoses.

5. Disconnect the fuel feed, vapor return and fuel return lines from the fuel tank using a fuel line disconnect tool.

6. Remove the bolts from the fuel filler neck with a ratchet wrench. Remove the filler neck.

7. Remove the gas tank. Place an automotive jack under the gas tank to support it. Remove the two retaining straps and lower the tank slightly to remove any electrical connections. Remove the tank from the vehicle.

8. Disconnect any electrical connections running from the fuel pump.

9. Remove the retaining collar from the fuel pump assembly using snap-ring pliers, contracting the retaining collar for removal.

10. Lift the fuel pump assembly from the fuel tank.

11. Remove the strainer from the bottom of the fuel pump assembly. Pry on the plastic tab with a small screwdriver to remove it.

12. Remove the fuel pump from the fuel level sending unit and fuel pressure sensor. Disconnect the electrical connections for the sending unit and pressure sensor. Remove the pressure sensor mounting bolts with a ratchet wrench and remove the pressure sensor. Pry the sending unit bracket away from the fuel pump with a small screwdriver.

13. Install the new fuel pump to the fuel level sending unit and fuel pressure sensor. Attach the sending unit bracket to the fuel pump. Install the fuel pressure sensor and replace the mounting bolts with a ratchet wrench. Connect any electrical connections that were removed in Step 12.

14. Place the strainer back in to the bottom of the fuel pump and engage the bottom locking tab to hold it in place.

15. Place the fuel pump assembly in to the fuel tank.

16. Install the retaining collar in the fuel pump assembly using snap-ring pliers, contracting the retaining collar for installation.

17. Place an automotive jack underneath the fuel tank, raise the tank and connect any electrical connections running to the fuel pump that were disconnected in Step 8.

18. Replace the gas tank. Place the tank in position and install the two retaining straps.

19. Place the fuel filler neck into position and install the mounting bolts with a ratchet wrench.

20. Connect the fuel feed, vapor return and fuel return lines to the fuel tank. The lines will connect after pushing them on to the appropriate positions on the fuel tank.

21. Connect the fuel filler hose and vapor return hoses that were disconnected in Step 4 and tighten the clamps with a screwdriver.

22. Raise the exhaust into position and install the rubber hangers to hold the exhaust in place.

23. Remove the jack stands and lower the rear of vehicle with an automotive jack.

24. Replace the fuel filler neck cap and connect the fuel pump electrical connector near the fuel tank.

25. Pour gas into the vehicle, start the engine and check for leaks.

References

• "Haynes Repair Manual: Chevrolet Cavalier 1995 thru 2002"; John H Haynes, Rob Maddox and Mike Stubblefield; 2003