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HOMESERVICE MANUALSCHEVROLET2001CAVALIER LS, 2.4 TREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 70 (ENGINE CONTROLS - BASIC DIAGNOSTIC PROCEDURES - 2.2L)FUEL SYSTEMSFUEL SYSTEM DIAGNOSIS (GASOLINE)DIAGNOSTIC PROCEDURE
2001 Chevrolet Cavalier LS, 2.4 T

Diagnostic Procedure

2001 Chevrolet Cavalier LS, 2.4 TSECTION Diagnostic Procedure
WARNING: This page is about a different car, the 2003 Pontiac Sunfire, 2003 Pontiac Grand Am, 2003 Oldsmobile Alero, and 2003 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Did you perform the Diagnostic System Check - Engine Controls. If yes, go to next step. If no, go to DIAGNOSTIC SYSTEM CHECK - ENGINE CONTROLS under SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS - 2.2L ALERO, CAVALIER, GRAND AM & SUNFIRE - GASOLINE article.
    2. CAUTION: Inspect the fuel system for damage or external leaks before proceeding with this diagnostic procedure.
  2. Turn ignition switch to RUN position, engine OFF. Command the fuel pump relay ON using a scan tool. Does the fuel pump operate? If yes, go to next step. If no, go to FUEL PUMP ELECTRICAL CIRCUIT DIAGNOSIS under FUEL SYSTEMS (GASOLINE) in SYSTEM & COMPONENT TESTING - 2.2L ALERO, CAVALIER, GRAND AM & SUNFIRE article.
    3. NOTE: Ensure adequate fuel is in the fuel tank before proceeding with this diagnostic procedure.
  3. Turn ignition switch to OFF position. Turn all accessories OFF. Connect Fuel Pressure Gauge (J 34730-1A), or equivalent, to the fuel pressure connection, located on the fuel rail. See Figure. Turn ignition switch to RUN position, engine OFF. Do not start the engine. Command the fuel pump relay ON using a scan tool. The fuel pump relay may need to be commanded ON a few times to obtain the highest possible fuel pressure. Observe the fuel pressure gauge with the fuel pump commanded ON. Is the fuel pressure 50-60 psi (345-414 kPa)? If yes, go to next step. If no, go to step  10.
    4. NOTE: The fuel pressure may vary slightly when the fuel pump stops operating. After the fuel pump stops operating, the fuel pressure should stabilize and remain constant.
  4. Monitor the fuel pressure gauge for one minute. Does the fuel pressure decrease by more than 5 psi (34 kPa)? If yes, go to step  7. If no, go to next step.
  5. Relieve the fuel pressure to 10 psi (69 kPa). Monitor the fuel pressure gauge for 5 minutes. Does the fuel pressure decrease by more than 2 psi (14 kPa)? If yes, go to step  20. If no, go to next step.
  6. Operate the vehicle within the conditions to reproduce the original symptoms. Monitor the O2 and the FUEL TRIM parameters using a scan tool. Does the scan tool parameters indicate a lean condition? If yes, go to step  13. If no, go to step  8.
  7. Turn ignition switch to OFF position. Remove the hose from the fuel pressure regulator. See Fig 1. Turn ignition switch to RUN position, engine OFF. Command the fuel pump relay ON using a scan tool. Inspect for a fuel leak from the fuel pressure regulator port. Is the fuel pressure regulator leaking fuel? If yes, go to step  19. If no, go to next step.
  8. Turn ignition switch to OFF position. Relieve the fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect the chassis fuel hoses from the engine compartment fuel pipes. See FUEL LINE QUICK CONNECT FITTINGS in REMOVAL & INSTALLATION - CAVALIER & SUNFIRE article. Install the Fuel Line Shut-off Adapters (J 37287), or equivalent, between the chassis fuel hoses and the engine compartment fuel pipes. Open the valves on the fuel pipe shut-off adapters. Turn ignition switch to RUN position, the engine OFF. Command the fuel pump relay ON using a scan tool. Bleed the air from the fuel pressure gauge. Command the fuel pump relay ON and then OFF. Close the fuel feed pipe shut-off valve. Monitor the fuel pressure gauge for one minute. Does the fuel pressure remain constant? If yes, go to step  16. If no, go to next step.
  9. Turn ignition switch to OFF position. Open the fuel feed pipe shut-off valve. Turn ignition switch to RUN position, engine OFF. Command the fuel pump relay ON and then OFF using a scan tool. Close the fuel return pipe shut-off valve. Monitor the fuel pressure gauge for one minute. Does the fuel pressure remain constant? If yes, go to step  19. If no, go to step  17.
  10. Is the fuel pressure more than 60 psi (414 kPa)? If yes, go to next step. If no, go to step  13.
  11. Turn ignition switch to OFF position. Relieve the fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect the fuel return hose from the engine compartment fuel return pipe. Place the open end of the flexible fuel return hose into an approved gasoline container. Turn ignition switch to RUN position, with the engine OFF. Monitor the fuel pressure gauge while the fuel pump is operating. Is the fuel pressure 50-60 psi (345-414 kPa)? If yes, go to step  18. If no, go to next step.
  12. Inspect the fuel rail return pipe and the fuel rail outlet passage for a restriction. Did you find and correct the condition? If yes, go to step  21. If no to step  19.
  13. Turn ignition switch to OFF position. Relieve the fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect the fuel return hose from the engine compartment fuel return pipe. Install the Fuel Line Shut-off Adapter (J 37287), or equivalent, between the fuel return hose and the engine compartment fuel pipe. Open the valve in the fuel pipe shut-off adapter. Turn ignition switch to RUN position, engine OFF. Bleed the air from the fuel pressure gauge. Monitor the fuel pressure gauge. Do not allow the fuel pressure to exceed 75 psi (517 kPa). Excessive pressure may damage the fuel system. Command the fuel pump relay ON using a scan tool. Slowly close the valve in the fuel return pipe shut-off adapter, while the fuel pump is operating. Does the fuel pressure increase to more than 60 psi (414 kPa)? If yes, go to step  19. If no, go to next step.
  14. Check the fuel filter and fuel feed pipe for a restriction. Did you find and correct the condition? If yes, go to step  21. If no, go to next step.
  15. Check the harness connectors and the ground circuits of the fuel pump for poor connections. Did you find and correct the condition? If yes, go to step  21. If no, go to next step.
  16. Remove the fuel sender assembly. See FUEL SENDER ASSEMBLY under FUEL SYSTEMS - GASOLINE in REMOVAL & INSTALLATION - CAVALIER & SUNFIRE article. Check the following items:
    • The fuel pump flex hose for damage.
    • The in-tank fuel pump harness connectors for poor connections.
    • The fuel strainer for a restriction.
    • The fuel tank for contaminants.

    Did you find and correct the condition? If yes, go to step  21. If no, go to step  20.

  17. Open the fuel return pipe shut-off valve. Turn ignition switch to OFF position. Raise the fuel rail, with the fuel lines connected. Turn ignition switch to RUN position, engine OFF. Command the fuel pump relay ON using a scan tool. Locate and replace the leaking fuel injector. After repair, go to step  21.
  18. Repair the restricted fuel return pipe. After repair, go to step  21.
    19. NOTE: Inspect for a missing or damaged "O" ring seal before replacing the fuel pressure regulator.
  19. Replace the fuel pressure regulator. After repair, go to step  21.
  20. Replace the fuel sender. After repair, go to next step.
  21. Operate the system to verify the repair. Did you correct the condition? If yes, system is okay at this time. If no, go to step  3.
Fig 1: Disconnecting Vent Pipe From Pressure Regulator
G00217333Courtesy of GENERAL MOTORS CORP.
RENDER: 1.0x

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Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.