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HOMESERVICE MANUALSCHEVROLET2002CAVALIER BASE, 4D SEDAN, 2.4 TREPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE PERFORMANCESYSTEMENGINE CONTROL SYSTEM TESTING & ENGINE COMPONENT TESTINGEMISSION SYSTEMS & SUBSYSTEMSFUEL TANK LEAK TESTDIAGNOSTIC PROCEDURES
2002 Chevrolet Cavalier Base, 4D Sedan, 2.4 T

Diagnostic Procedures

2002 Chevrolet Cavalier Base, 4D Sedan, 2.4 TSECTION Diagnostic Procedures
  1. Perform Diagnostic System Check - Engine Controls. See DIAGNOSTIC SYSTEM CHECK - ENGINE CONTROLS under SELF-DIAGNOSTIC SYSTEM in appropriate SELF-DIAGNOSTICS article.
    2. NOTE: Before performing this procedure, place a dry chemical (class B) fire extinguisher near the work area.
  2. Raise the vehicle. Inspect the fuel tank and fuel pipes for damage or external leaks. Did you find fuel leaking from the fuel tank? If yes, go to step  7. If no, go to next step.
  3. Turn ON the ignition, with the engine OFF. With a scan tool, command the fuel pump ON. Inspect for fuel leaking from the fuel pipes. Did fuel leak from the fuel pipes? If yes, go to step  8. If no, go to next step.
  4. Install the Fuel Tank Cap Adapter (J 41415-40). Connect the EVAP Pressure/Purge Diagnostic Station (J 41413) to the fuel tank cap adapter. With a scan tool, seal the EVAP system. DO NOT exceed 15 in. H2O. With the EVAP pressure/purge diagnostic station, pressurize the fuel tank. Did fuel leak from the fuel tank? If yes, go to step  7. If no, go to next step.
  5. With the EVAP pressure/purge diagnostic station, maintain pressure in the fuel tank. The fuel tank may need to be partially lowered. With the Ultrasonic Leak Detector (J 41416), test for leaks above the fuel level in the following locations.
    • The fuel tank, fill limiter vent valve, pressure relief valve and rollover valves.
    • The fuel sender housing and fuel sender seal.
    • The Fuel Tank Pressure (FTP) sensor seal.
    • The EVAP vapor pipes.
    • The fuel fill pipe and hose.

    Did you locate a fuel leak? If yes, go to next step. If no, see DIAGNOSTIC AIDS .

  6. Repair the system as necessary. After repairs, system is okay.
  7. Replace the fuel tank. After repairs, system is okay.
  8. Replace the leaking fuel pipe. After repairs, system is okay.
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When to See a Mechanic

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.