Replacing The Fuel Pump In A 96 Cavalier: Step-By-Step Guide

The fuel pump in a 96 Chevy Cavalier is located inside the fuel tank. To change the fuel pump, first relieve the fuel system pressure using the recommended procedure. Disconnect the negative battery cable and drain the fuel tank. Remove the fuel tank from the vehicle and hold the modular fuel sender assembly down. Remove the snap-ring from the designated slots located on the retainer. Remove the external fuel strainer and detach the Connector Position Assurance (CPA) piece from the electrical connector. Detach the fuel pump electrical connector and gently release the tabs on the sides of the fuel sender at the cover assembly. Lift the cover assembly out far enough to detach the fuel pump electrical connection. Rotate the fuel pump baffle counterclockwise and remove the baffle and pump assembly from the retainer. Slide the fuel pump outlet out of the slot, then remove the fuel pump outlet seal. To install the new fuel pump, reverse these steps.

Relieve the fuel system pressure

To relieve the fuel system pressure of your 1996 Chevy Cavalier, follow these steps:

First, pull the fuel pump relay, and start your car, letting it run until it dies. This will depressurize the fuel system.

Next, support the fuel tank and take loose the straps that hold it up. Slowly lower the tank until you can unhook the tank filler hose and overflow hose by taking the clamps off and sliding the hoses off. Lower the tank some more, and unhook the wire connection.

Once you get it down, it's easiest to empty as much fuel as you can; as this will help you get it back into place. The fuel pump is inside the tank, which locks into place with a 1/8th turn. You will need a hammer and a brass punch for this job, as it needs to be tapped around to unlock.

Disconnect the negative battery cable

To disconnect the negative battery cable, you will need to locate the battery. On a Chevy Cavalier, the battery is typically located in the engine bay, near the front of the vehicle. Once you have located the battery, look for the negative battery cable. This will be the black cable connected to the negative (-) terminal on the battery. Using a wrench or socket, loosen the nut that secures the cable to the terminal and remove the cable. Be sure to disconnect the negative cable first to avoid any potential electrical shorts.

It is important to take safety precautions when working on a car battery. Always wear protective gear, such as gloves and eye protection, and ensure that you have a basic understanding of car electrical systems before proceeding. If you are unsure about any aspect of the task, it is best to consult a qualified mechanic.

Once the negative battery cable is disconnected, you can proceed with the next steps of changing the fuel pump. It is worth noting that working on a fuel pump can be dangerous due to the presence of flammable liquids and gases. Always refer to the appropriate service manual for your vehicle and take the necessary safety precautions.

After disconnecting the negative battery cable, the next steps in changing the fuel pump on a 1996 Chevy Cavalier involve relieving the fuel system pressure using the recommended procedure and draining the fuel tank. These steps are crucial for safety and should not be skipped. Once the fuel tank is drained, you can proceed to remove the fuel tank from the vehicle and access the fuel pump for replacement.

Drain the fuel tank

To drain the fuel tank of a 1996 Chevy Cavalier, follow these steps:

• Relieve the fuel system pressure using the recommended procedure.
• Disconnect the negative battery cable.
• Drain the fuel tank, then remove the fuel tank from the vehicle.
• Be aware that the reservoir bucket is full of fuel. It must be tipped slightly during removal to avoid damage to the float.

Draining the fuel tank is a crucial step in changing the fuel pump of a 1996 Chevy Cavalier. It is important to follow the correct procedure and take the necessary precautions when working with fuel to ensure safety and avoid any damage to the vehicle.

Remove the fuel tank from the vehicle

To remove the fuel tank from the vehicle, follow these steps:

• Ensure the vehicle is on a level surface and engage the parking brake.
• Block the drive wheels and place chocks around the wheels.
• Relieve the fuel system pressure using the recommended procedure.
• Disconnect the negative battery cable.
• Drain the fuel tank.
• Loosen the filler neck and vent to the tank.
• Disconnect the wiring.
• Loosen the bolts holding the straps that hold the tank in place. Do not remove them yet.
• Jack up the vehicle and place jack stands for support.
• Slowly lower the tank, being careful not to kink any hoses or damage any wiring.
• Once the tank is lowered, remove the bolts holding the straps and carefully remove the tank.

Note: It is important to work with caution when handling the fuel tank as it contains flammable liquids. Ensure proper ventilation and have a fire extinguisher nearby.

Remove the fuel pump electrical connector

To remove the fuel pump electrical connector, first relieve the fuel system pressure using the recommended procedure. Next, disconnect the negative battery cable. Drain the fuel tank and remove the fuel tank from the vehicle. While holding the modular fuel sender assembly down, remove the snap-ring from the designated slots located on the retainer. Warning: The modular fuel sender assembly 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.

Now, remove the external fuel strainer. Detach the Connector Position Assurance (CPA) piece from the electrical connector and detach the fuel pump electrical connector. 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 tabs in the same manner.

Lift the cover assembly out far enough to detach the fuel pump electrical connection.

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