2000 - 2005 GM 2.2L Ecotec Fuel Pump Diagnosis & Replacement (Chevy Cavalier & Pontiac Sunfire)

When encountering a sudden crank, no start, condition - this video covers the fuel system diagnosis involved to identify the root cause of this sort of problem (which is almost always the fuel pump / fuel sender assembly. The vehicle shown is a 2004 Chevy Cavalier but the parts are common for all 2000, 2001, 2002, 2003, 2004, and 2005 models years for both Pontiac Sunfire and Chevrolet Cavalier.

What we cover in this video
Fuel pump / fuel system electrical diagnosis
Fuel tank removal / reinstallation
Exhaust heat shield rivet removal and replacement
Fuel pump removal / installation

The eBay and Amazon search links below are paid links, for which I may be compensated and earn a commission, if you choose to buy the parts and tools shown in this video thru them:

Here is the ACDelco MU1374 / GM 88967294 fuel sender assembly: https://ebay.us/eivSyB or https://amzn.to/3AiOdUD

For the replacement fuel filter ACDelco GF578 / GM 25121293: https://ebay.us/1xkLSl or https://amzn.to/3Cqswok

The replacement fuel tank locking ring is ACDelco TR7 / GM 25691383: https://ebay.us/uHrb1J or https://amzn.to/3wrSrrQ

The replacement exhaust shield rivets GM 11569663 can be found here: https://ebay.us/tXxM5S

The OTC 5630 fuel pressure tester I used can be found at this eBay affiliate link: https://ebay.us/nIc7vz and Amazon: https://amzn.to/3pXotta

If you lost the fuel pressure service port cap, GM 17105652 (now discontinued), here's an eBay affiliate search link for that: https://ebay.us/Ls5XG1

For the GM J-body factory service manual, here's an eBay affiliate search link: https://ebay.us/jR8b1r

And if I've saved you some $$ here, consider some coins for the coffee tip-jar! https://ko-fi.com/drshock

2000 2001 2002 2003 2004 2005

Chapters:
0:00 - Problem overview
0:47 - Fuel system pressure check
2:00 - Fuel system electrical checks
4:55 - Service manual procedure overview
6:28 - Fuel system parts identification and location
8:16 - Removing the EVAP canister from the body
9:03 - Removing exhaust shield rivets
11:14 - Fuel fill hose disconnect and tank siphoning
15:54 - Disconnecting electrical, vent lines, & fuel lines
22:11 - Releasing the fuel tank straps
23:50 - Dropping the fuel tank
26:45 - Fuel tank inspection and line disconnects
30:28 - Removing the fuel sender assembly
32:31 - Replacement part numbers
33:35 - Service manual procedure overview
35:38 - Fuel tank prep and fuel sender assembly installation
40:45 - Reinstalling the fuel tank to the body
45:38 - Reconnecting hose, pipes, shield, and harness
56:25 - Air purge and final testing

#drshock #cavalier #sunfire

Disclaimer: DrShock, the alias for the human content creator for this YouTube channel, is not responsible for any damages, injuries, losses, or liabilities associated with any repairs, upgrades, or maintenance performed on yours, or any other, vehicle whatsoever. No warranty, express or implied, is made as to the accuracy or completeness of any information provided within this channel. Viewing and using the “as-is" information of this channel is totally at your own risk. Always wear personal protection equipment and follow appropriate vehicle manufacturer service manual guidelines with original manufacturer parts only when performing any repairs, upgrades, or maintenance upon any vehicle.