GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2009 🢒 Optra - Mexico 🢒 Engine 🢒 Engine Controls and Fuel - 2.0L (Diesel) 🢒 Fuel Pump Replacement

Removal Procedure

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


    Object Number: 1962985 Size: SH
  1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief.

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

  2. Disconnect the negative battery cable.
  3. Remove the rear seat. Refer to Rear Seat Cushion Replacement.
  4. Remove the fuel pump access cover.

    5. Object Number: 1962986 Size: SH
  5. Disconnect the electrical connector at the fuel pump assembly.
  6. Disconnect the fuel outlet line.
  7. Disconnect the fuel tank return line.
  8. Turn the lock ring counterclockwise to clear the tank tabs.
  9. Remove the fuel pump assembly from the tank.

Installation Procedure

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


    Object Number: 1962987 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. Install the rear seat. Refer to Rear Seat Cushion Replacement.
  10. Connect the negative battery cable.
  11. Prime the fuel system. Refer to Fuel System Priming.
  12. Perform an operational check of the fuel pump.