GM Corsica/Beretta 1988-1996 Repair Guide

Fuel Pump

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The electric fuel pump is attached to the fuel sending unit. The pump used on the 2.0L and 2.2L engines with throttle body injection is a low pressure pump that ranges from 4-13 psi.

REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6 and 7

  1. Properly relieve the fuel system pressure.
  2.  
  3. If not already done, disconnect the negative battery cable.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Remove the fuel tank, as outlined later in this section.
  8.  
  9. Remove the fuel lever sending unit and pump assembly by using the proper tool to turn the cam lock ring counterclockwise. Lift the assembly from the fuel tank and remove the fuel pump from the fuel level sending unit.
  10.  



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Fig. Fig. 1: View of the fuel level sender locking cam tool that is used on 1988 vehicles



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Fig. Fig. 2: A different tool is used to unlock the fuel level sender cam on 1989-91 vehicles

  1. Pull the fuel pump up into the attaching hose or pulsator while pulling outward away from the bottom support. After the pump is clear of the bottom support, pull the pump assembly out of the rubber connector or pulsator for removal.
  2.  



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Fig. Fig. 3: Fuel level meter replacement - 1988-90 vehicles



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Fig. Fig. 4: Exploded view of the fuel level/meter assembly - 1991 vehicles



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Fig. Fig. 5: Cross-sectional view of the in-tank electrical pump and sender - 1988 vehicles



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Fig. Fig. 6: Typical intake fuel pump and fuel sender assembly - 1989 vehicles



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Fig. Fig. 7: In-tank electric fuel pump and fuel level sender - 1990-91 vehicles

To install:
  1. Push the pump into the attaching hose.
  2.  
  3. Install the fuel level sending unit and pump assembly into the tank assembly. Use new O-ring during reassembly.
  4.  


WARNING
Be careful not to fold over or twist the strainer when installing the sending unit as it will restrict fuel flow. Also, be careful the strainer does not block full travel of the float arm.

  1. Install the cam lock over the assembly and lock by turning clockwise.
  2.  
  3. Install the fuel tank, as outlined later in this section.
  4.  
  5. Carefully lower the vehicle, then connect the negative battery cable.
  6.  

TESTING



See Figure 8

2.0L Engines
  1. Properly relieve the fuel system pressure.
  2.  
  3. With the engine OFF off, remove the TBI cover and gasket.
  4.  
  5. Uncouple the fuel supply flexible hose in the engine compartment and attach a gauge between the steel line and the flexible hose. Tighten the gauge inline to ensure no leaks occur during testing.
  6.  
  7. Start the engine and note the reading on the gauge. The pressure should be 9-13 psi.
  8.  
  9. Remove the gauge and reconnect the fuel line. Start the engine and check for leaks.
  10.  

2.2L Engines
  1. Turn the ignition to the OFF position.
  2.  
  3. Make sure the fuel tank quantity is sufficient.
  4.  
  5. Install pressure gauge J 29658-B or BT-8205 or equivalent to the fuel line as illustrated.
  6.  



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Fig. Fig. 8: Fuel pressure can be checked using an inexpensive pressure/vacuum gauge

  1. Apply battery voltage to the fuel pump test connector using a 10 amp fused jumper wire.
  2.  
  3. Note the fuel pressure which should be 9-13 psi.
  4.  

 
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