Katerina Swanson
If you need to replace the fuel pump on a 1991 Cavalier, you'll need to drain the fuel tank, disconnect the battery terminal, and remove the fuel filler hose from the tank. You'll then need to remove the old fuel pump and replace it with a new one, making sure to bolt it securely into place. Finally, you'll need to reconnect the fuel lines and the wiring harness, and ensure that everything is working properly.
| Characteristics | Values |
|---|---|
| Disconnect the positive battery terminal | Disconnect the positive battery terminal |
| Siphon out the gas tank | Siphon out the gas tank and let it run into an empty gas can |
| Drain the fuel tank | Drain the fuel tank |
| Disconnect the quick-connect fitting at the fuel filter | Disconnect the quick-connect fitting at the fuel filter |
| Disconnect the fuel return pipe quick-connect fitting | Disconnect the fuel return pipe quick-connect fitting |
| Remove the rubber exhaust hangers | Remove the rubber exhaust hangers |
| Allow the exhaust system to rest on the rear axle | Allow the exhaust system to rest on the rear axle |
| Remove the exhaust heat shield | Remove the exhaust heat shield |
| Loosen the fuel filler hose clamp at the fuel tank | Loosen the fuel filler hose clamp at the fuel tank |
| Disconnect the fuel filler hose from the fuel tank | Disconnect the fuel filler hose from the fuel tank |
| Relieve the fuel system pressure | Relieve the fuel system pressure |
| Pull the fuel pump up and let it drain into the tank | Pull the the fuel pump up and let it drain into the tank before you remove it from the tank |
| Bolt the new pump into place | Bolt the new pump into place onto the gas tank |
| Reconnect the fuel lines and the wiring harness | Reconnect the fuel lines and the wiring harness |
| Reconnect the metal straps that hold the tank in place | Reconnect the metal straps that hold the tank in place |
| Tighten the strap bolts | Tighten the strap bolts so the tank is secured to the frame of the vehicle |
| Reconnect the battery terminal | Reconnect the battery terminal |
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What You'll Learn
Disconnect the positive battery terminal
To disconnect the positive battery terminal of your 1991 Cavalier, park on a flat, level surface. Disconnect the positive battery terminal, and place the mechanic’s ramps behind the rear tires of the car.
Before you disconnect the battery, make sure you have the correct tools and safety equipment. You will need a wrench or socket set to disconnect the battery terminal. You should also wear safety goggles and gloves to protect your eyes and hands.
When you are ready to disconnect the battery, locate the positive terminal. It will be marked with a "+" sign. Use your wrench or socket set to loosen the nut that secures the terminal to the battery post. Do not allow the wrench to touch any part of the car's body or frame, as this could cause a short circuit. Once the nut is loose, remove the terminal from the battery post.
After you have disconnected the positive battery terminal, place the mechanic’s ramps behind the rear tires of the car. This will provide you with access to the fuel pump.
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Siphon out the gas tank
To remove and replace the fuel pump for a 1991 Cavalier, you will need to siphon out the gas tank. Park your car on a flat, level surface and disconnect the positive battery terminal. Place mechanic's ramps behind the rear tires of the car. Siphon out the gas tank and let it run into an empty gas can. If you have purchased a siphon, it will have instructions on how to use it. Read these and follow them carefully.
Once the gas tank has been siphoned, you will need to drain the fuel tank further. Raise the vehicle and disconnect the quick-connect fitting at the fuel filter. Disconnect the fuel return pipe quick connect fitting. Remove the rubber exhaust hangers and allow the exhaust system to rest on the rear axle. Remove the exhaust heat shield and loosen the fuel filler hose clamp at the fuel tank. Disconnect the fuel filler hose from the fuel tank.
Now that the gas tank is empty, you can begin to remove the fuel pump. There are bolts holding the fuel pump onto the gas tank. The cylinder has two tubes coming out of it. Pull the fuel pump up and let it drain into the tank before you remove it. Make sure that no debris gets into the tank.
Finally, replace the fuel that you siphoned out and reconnect the battery terminal. Drive down from the ramps and make sure that everything is working properly.
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Drain the fuel tank
To drain the fuel tank of your 1991 Cavalier, park on a flat, level surface and disconnect the positive battery terminal. Place mechanic’s ramps behind the rear tires of the car. Siphon out the gas tank and let it run into an empty gas can. If you purchased a siphon, it will have instructions on how to use it. Read these and follow them. Remove the gas from your vehicle into the gas can.
Next, raise the vehicle. Disconnect the quick-connect fitting at the fuel filter. Disconnect the fuel return pipe quick-connect fitting. Remove the rubber exhaust hangers. Allow the exhaust system to rest on the rear axle. Remove the exhaust heat shield. Loosen the fuel filler hose clamp at the fuel tank. Disconnect the fuel filler hose from the fuel tank.
Before you remove the fuel pump from the tank, pull it up and let it drain into the tank. Make sure that no debris gets into the tank.
Finally, replace the fuel that you siphoned out and reconnect the battery terminal. Drive down from the ramps and make sure that everything is working properly.
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Disconnect the quick-connect fitting at the fuel filter
To disconnect the quick-connect fitting at the fuel filter, you will need to use a special tool. Wrap shop towels around the hoses to catch any gasoline spillage. Lubricate the fuel tube nipple with clean 30 weight engine oil. Place the special tool between the shoulder of the disconnect tool and the top of the quick-connect body. Push down on the special tool, and you should see a slight downward movement of the quick-connect fitting until the retainer in the fitting contacts the fuel tube nipple shoulder. Once the retainer contacts the shoulder, all movement should stop. If the quick-connect fitting comes off of the fuel rail, attach it according to the installation procedure.
To disconnect the fitting from the fuel rail, slightly twist the fitting and while maintaining downward pressure on the special tool. If the locking retainer is stuck in the release position due to mushrooming of the disconnect tool or dirt accumulation, replace the fitting and tube assembly.
If you are having trouble disconnecting the fitting, pull the hose towards the object you are trying to disconnect it from, put the tool on the line, slide the tool towards the hose hard, and with a slight bit of force, slide the tool and line together away from the object it's connected to. If it still doesn't let go, try again but twist the disconnect tool a little bit on the line.
If you are disconnecting a GM quick-disconnect fuel filter, you may need to squeeze the two prongs together and pull out. If it has a metal quick fitting, you will need a special tool.
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$142.5
Remove the exhaust heat shield
To remove the exhaust heat shield, first remove the rubber exhaust hangers. Allow the exhaust system to rest on the rear axle. Then, remove the exhaust heat shield.
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Frequently asked questions
Park your car on a flat, level surface and disconnect the positive battery terminal. Place the mechanic's ramps behind the rear tires of the car. Siphon out the gas tank and let it run into an empty gas can.
Take your new pump and bolt it into place onto the gas tank. Take a small jack with you when you slide back under the car to reconnect the fuel lines and the wiring harness. You will need the jack to hold up one end of the tank while you reattach the metal straps that hold the tank in place.
You will need a small jack, a socket wrench, and a mechanic's ramp.
Make sure that no debris gets into the tank.
If your engine is not getting enough fuel, you may need to replace the fuel pump.
