How to Remove the Fuel Tank From a 2003 Chevy Cavalier

The Chevrolet Cavalier was first introduced in 1982. The 2003 Chevrolet Cavalier came equipped with a 2.2-liter in-line four-cylinder engine, capable of producing 140-horsepower. The Chevrolet Cobalt replaced the Cavalier after 2005. The fuel tank on the 2003 Cavalier is usually removed because of tank damage or to access the in-tank fuel pump. The fuel tank should be no more than half-full when attempting to remove or install the tank or it becomes very difficult to lift and maneuver.

Instructions

Removal

1

Raise the rear of the Cavalier with a jack. Place jack stands beneath the rear axle cross member. Lower the car onto the jack stands.

2

Lie beneath the bumper of the car and position yourself so you can access the bottom of the fuel tank. Loosen the clamp on the large hose protruding to the rear of the tank. Remove the hose from the tank.

3

Slide your jack beneath the fuel tank. Insert a plank of wood between the jack head and the fuel tank. Raise the jack up to the bottom of the fuel tank, being careful not to push upward on the bottom of the tank.

4

Remove the right and left fuel-tank mounting strap bolts with a ratchet, socket and extension. Move the fuel tank straps downward and off to either side of the tank with one hand. Balance the fuel tank on the jack and plank with your second hand.

5

Lower the tank about halfway between the bottom of the car and the ground. Loosen the small hose clamps from the fuel pump with a ratchet and socket. Disconnect the hoses from the fuel pump completely. Disconnect the electrical connector from the top of the fuel pump, using your fingers to depress the release tab.

6

Lower the fuel tank onto a piece of cardboard. The cardboard will prevent sparks from being created when you slide the fuel tank out from beneath the car.

Installation

7

Slide the tank on a large piece of cardboard under the lifted car. Set the tank up onto the jack with the plank of wood between the jack head and the tank. Lift the tank about halfway up between the bottom of the car and the ground.

8

Install the small hoses onto the fuel pump and tighten the clamps with a ratchet and socket, until they are snug. Do not over tighten the fuel hoses. Connect the electrical connector to the fuel tank by hand, and push it on until it audibly clicks into place. Lift the tank up against the bottom of the car, being careful not to press on the bottom of the tank. Install the large fuel filler hose to the rear of the fuel tank, and tighten the hose clamp until it is snug with a ratchet and socket.

9

Push the fuel tank straps into position beneath the fuel tank. Install and tighten both fuel tank strap bolts to 65 foot-pounds of torque with a 1/2-inch drive ratchet, socket and extension.