GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2005 🢒 Optra 🢒 Engine 🢒 Engine Controls - 1.4L DOHC 🢒 Fuel Pump Replacement

Removal Procedure

    Caution: Refer to Relieving Fuel Pressure Caution in the Preface section.


    Object Number: 1289386 Size: SH
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief .

    2. Caution: Refer to Battery Disconnect Caution in the Preface section.

  2. Disconnect the negative battery cable.
  3. Remove the rear seat. Refer to Rear Seat Cushion Replacement in Seats.
  4. Remove the fuel pump access cover.
  5. Disconnect the electrical connector at the fuel pump assembly.
  6. Disconnect the fuel outlet line.
  7. Disconnect the fuel tank return line.

    8. Object Number: 1289398 Size: SH
  8. Turn the lock ring counterclockwise to clear the tank tabs.
  9. Remove the fuel pump assembly from the tank.

Installation Procedure

    Caution: Refer to Safety Glasses Caution in the Preface section.


    Object Number: 1289386 Size: SH
  1. Clean the gasket mating surface on the fuel tank.
  2. Position the new gasket in place.
  3. Install the fuel pump into the fuel tank in the same location as removed for ease of line and connector installation.
  4. Position the lock ring in place and turn it clockwise until it contacts the tank stop.
  5. Connect the fuel pump assembly connector.
  6. Install the fuel pump outlet line.
  7. Install the fuel tank return line.
  8. Install the fuel pump access cover.
  9. Connect the negative battery cable.
  10. Perform an operational check of the fuel pump.
  11. Install the rear seat. Refer to Rear Seat Cushion Replacement in Seats.