Here's a general outline of the process. Specific steps and tool requirements may vary slightly depending on the engine type (1.6L or 1.5L) and the Aveo's trim level. Always consult a repair manual specific to your vehicle year and engine for precise instructions and safety precautions. A Haynes or Chilton manual is a good resource.
1. Safety First:
* Disconnect the negative battery terminal. This is crucial to prevent sparks and electrical hazards.
* Work in a well-ventilated area. Fuel fumes are flammable and potentially harmful.
* Wear safety glasses and gloves.
* Have a fire extinguisher readily available.
2. Prepare the Vehicle:
* Raise and securely support the vehicle. Use jack stands, never rely solely on a jack.
* Locate the fuel pump access panel. This is usually located under the rear seat (some models may require dropping the fuel tank). Consult your repair manual for the exact location.
3. Access the Fuel Pump:
* Remove the rear seat (if necessary).
* Locate and disconnect the fuel lines. This will involve carefully releasing clamps. Have rags ready to absorb any spilled fuel. Be prepared for some fuel pressure release; this pressure may be relieved by carefully depressing the fuel pressure relief valve; consult your repair manual.
* Disconnect the electrical connector to the fuel pump.
* Remove the fuel pump access cover.
4. Remove the Fuel Pump:
* This step varies significantly depending on your Aveo's model. Some models have a retaining ring and others may require removing the fuel pump assembly from the top. Your repair manual will show the specific method for your car. It may involve removing the fuel pump assembly with the pump still attached.
* Carefully remove the fuel pump assembly from the tank.
5. Install the New Fuel Pump:
* Install the new fuel pump assembly, ensuring it's properly seated and aligned.
* Reconnect the fuel lines, ensuring they're securely clamped.
* Reconnect the electrical connector.
* Reinstall the access cover.
* Reinstall the rear seat (if necessary).
6. Reassembly and Testing:
* Lower the vehicle.
* Reconnect the negative battery terminal.
* Check for leaks around the fuel lines.
* Start the engine and check for any unusual noises or fuel leaks.
* Verify that the fuel pressure is correct using a fuel pressure gauge (this may require specialized tools).
Important Notes:
* Fuel pumps are often sold as complete assemblies, including the sending unit and fuel level sensor. Replacing just the pump might not be feasible.
* Some fuel pumps require priming before starting the engine. Refer to the new fuel pump's instructions.
* Improper installation can lead to serious problems, including fuel leaks and engine damage.
This is a simplified overview. Refer to a repair manual specific to your 2004 Chevrolet Aveo for detailed instructions, diagrams, and safety precautions. Taking shortcuts can be dangerous and expensive. If you have any doubts about your ability to complete this repair safely and correctly, seek professional help.
