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Unread 10-08-2012, 12:01 AM   #1
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Default Fuel Pump Replacement ?

I replaced my fuel pump after it failed on me. My car only fills up to the 42liter mark although I have a 52 liter tank, what gives?

Also, I notice after a cold start sometimes my car hesitates before moving then kicks in and is fine. It also shakes a bit at this point. Is this the fuel pump too do you think? I tried cleaning the solenoids but they weren't really dirty so I have no clue why I'm getting clicked back at 42 litres.

Any ideas would be great, thanks.

03 cavalier.

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Unread 10-12-2012, 06:36 PM   #2
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My cars doing the same... I have a 98 buick Lesabre and I start it up and it putters and pressing the gas the rpms struggle when in iddle.. then a few more minutes everything seems to be alright... Did you replace the fuel filter?


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Originally Posted by chevymeister View Post
I replaced my fuel pump after it failed on me. My car only fills up to the 42liter mark although I have a 52 liter tank, what gives?

Also, I notice after a cold start sometimes my car hesitates before moving then kicks in and is fine. It also shakes a bit at this point. Is this the fuel pump too do you think? I tried cleaning the solenoids but they weren't really dirty so I have no clue why I'm getting clicked back at 42 litres.

Any ideas would be great, thanks.

03 cavalier.

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Unread 10-13-2012, 02:22 AM   #3
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-Replace your fuel filter see if that helps

-Check fuel pressure

- Check and replace fuel pressure regulator

- If it's still acting up, Then it's your fuel pump

Your vac compressure could be going out too.....

Please advise...

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Unread 01-15-2013, 12:36 AM   #4
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Today I got around to taking the gas tank out of my car, checking the charcoal canister, the purge valve in the front, the vent solenoid, all the hoses... All clean. Maybe wonder if the marker just isn't bobbing right.

Also, I have been trying to diagnose a p0440 (massive vacuum leak) for awhile now and just can't figure it out. I've taken apart my whole evap system other than the lines running to and from the engine. Can something like a canister cause something like this? Or maybe a solenoid is failing?

I hate evap systems >

Last edited by chevymeister; 01-15-2013 at 12:49 AM.

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Unread 01-15-2013, 01:11 AM   #5
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To properly diagnose EVAP you need a smoke machine. I've managed a few fixes but it's hard work. I made up a low pressure, 1 psi tester, but all I can check is if it's leaking, not where.

Gas cap, rusted filler neck, or a leaking hose or valve. Carbon canister won't cause it.
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Unread 01-15-2013, 12:07 PM   #6
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I changed my gas cap already. My the filler tube all the way down to to the gas cap looks slightly rusty but not exactly any worse than my brake lines are. It didn't spike any curiosity after looking at it.

Ugh, this is going to be fun.

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Unread 01-15-2013, 07:29 PM   #7
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So my fuel pressure regulator isn't leaking or anything. If I want to make sure it's good I take the vacuum hose off while the cars running and make sure gas doesn't leak out? I took out my fuel pump and since it's warrantied I will be replacing it tomorrow just to make sure the sensor is reading fine. I measured with a multimeter the sensor connection and was reading 5 volts so I know the pump is receiving the correct amount of voltage. Might as well go get some solenoids/cannister from a scrapyard tomorrow. I'll see if it works.

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Unread 01-15-2013, 11:22 PM   #8
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The fuel regulator can leak internally and cause an increase in fuel consumption.

If you pull the hose off while it's running it should be dry, any fuel and it should be replaced.
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Unread 01-15-2013, 11:57 PM   #9
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Thanks man, I appreciate it.

I'll swap my fuel pump then get everything together and check the regulator. I'll update in a few days.

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Unread 01-16-2013, 12:06 AM   #10
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I disagree on needing a smoke machine to diag evap small leaks can be a pain, but normally big leaks are easily identified. If you getting a massive leak code, but have inspected the whole system and found no signs of leak then likely the problem is one of 3 things. 1. You missed part of the system when inspecting. 2. The system actually has no leak and the vacuum switching valve is bad. 3. The tank could be equiped with a internal rollover valve which could be damaged or broken off.

The vacuum switching valve is pretty common if it fails the computer will think it's commanding vacuum to the tank, but in actuallity no vacuum is reaching the tank meaning it does not see a vacuum increase and believes there is a large leak causing it to not pull a vacuum. Some vehicles have one valve located in the engine compartment off a vacuum source from the intake. Other cars have 2 one at the front of the car off the intake another by the charcoal canister in the rear.


If the car has a internal rollover valve in the tank it can be very hard to condem. Usually it breaks of and can be seen floating around in the tank after a accident. Sometimes they just leak which can cause a evap leak. A roll over valve can be hard to identifiy even with a smoker because usually the smoke gets filtered through the petrol from the evap system before pressure leaks out the valve. When pressureized if under the car it will usually create a faint fuel smell with no smoke do to the fumes being pushed out. In that case I usually request a r&r for further inspection. Only problem is roll over valve normally means it needs a new tank.
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