Safety First:
* Disconnect the negative battery terminal. This prevents accidental sparks and shorts.
* Work in a well-ventilated area. Fuel fumes are dangerous.
* Wear safety glasses and gloves.
* Have a fire extinguisher nearby.
General Steps (Consult your repair manual for precise details and diagrams):
1. Prepare the Vehicle: Park on a level surface, engage the parking brake, and chock the wheels.
2. Access the Fuel Pump: This usually involves dropping the fuel tank. The specifics vary depending on the Cavalier's body style (coupe, sedan). You'll likely need to:
* Remove the rear seat (if necessary). This will give you access to the fuel tank straps.
* Locate the fuel tank straps. These secure the tank to the vehicle's undercarriage.
* Disconnect the fuel lines: This is CRUCIAL. You'll need specialized fuel line disconnect tools to avoid damaging the lines. Be prepared for some fuel spillage; use absorbent material. Note where the lines connect – you'll need to reconnect them in the same manner.
* Disconnect the electrical connector to the fuel pump.
* Lower the fuel tank: This often requires carefully supporting the tank as you loosen the straps. You might need a jack and jack stands to safely lower it.
3. Remove the Fuel Pump: The fuel pump is usually accessed through an access panel on top of the fuel tank. You'll likely need to:
* Remove the access panel. This may involve removing bolts or using special tools.
* Remove the fuel pump retaining ring or bolts.
* Carefully lift out the fuel pump assembly. This assembly will include the pump, filter, and sending unit (fuel level gauge).
4. Install the New Fuel Pump:
* Carefully install the new fuel pump assembly into the tank, ensuring it sits correctly.
* Replace the retaining ring or bolts.
* Reinstall the access panel.
5. Reinstall the Fuel Tank:
* Carefully raise the fuel tank back into position.
* Reconnect the fuel lines. Double-check that they are securely attached and seated properly. Leaking fuel is extremely dangerous.
* Reconnect the electrical connector to the fuel pump.
* Reconnect the fuel tank straps.
6. Reconnect the Battery: Reconnect the negative battery terminal.
7. Prime the Fuel System (Crucial): After reconnecting the battery, you'll likely need to prime the fuel system. This might involve turning the ignition key to the "on" position several times (without starting the engine) to allow the pump to build pressure. Consult your repair manual for the specific priming procedure.
8. Test the Fuel System: Start the engine and listen for the fuel pump to run. Check for any fuel leaks. If everything seems correct, drive the car for a short distance to ensure there are no problems.
Important Considerations:
* Fuel pressure: You might need a fuel pressure gauge to check the fuel system pressure before and after the replacement.
* Fuel pump relay: A faulty fuel pump relay can also cause fuel pump problems. Testing the relay may be necessary.
* Fuel filter: While you're at it, consider replacing the fuel filter. This is usually a separate component but is often changed at the same time as the fuel pump.
This is a simplified overview. Again, using a repair manual specific to your 1996 Chevy Cavalier is absolutely crucial for a safe and successful repair. If you're not comfortable with this type of repair, it's best to have a qualified mechanic perform the work. Improperly installing a fuel pump can lead to serious damage or injury.
