GM Metro/Sprint 1985-1993 Repair Guide

Electric Fuel Pump

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REMOVAL & INSTALLATION



See Figure 1



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Fig. Fig. 1: Fuel pump and sending unit removal

  1. Relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and support the vehicle safely.
  6.  
  7. Drain the fuel tank by pumping or siphoning the fuel out through the fuel feed line (tank to fuel filter line).
  8.  
  9. Remove the tank from the vehicle.
  10.  
  11. Remove the fuel feed and return clamps and hoses from the fuel pump assembly.
  12.  
  13. Remove the attaching screws from the fuel pump assembly and remove the assembly with the gasket from the fuel tank.
  14.  
  15. Remove the mounting screw from the fuel pump motor assembly. Remove the fuel pump motor connectors and remove the fuel pump motor from the fuel pump assembly.
  16.  

To install:
  1. Install the fuel pump motor connectors. Install the fuel pump motor on the fuel pump assembly and tighten the mounting screw.
  2.  
  3. Install the assembly with the gasket on the fuel tank. Install the attaching screws and tighten securely.
  4.  
  5. Install the fuel feed and return clamps and hoses on the fuel pump assembly.
  6.  
  7. Install the fuel tank in the vehicle.
  8.  
  9. Lower the vehicle and connect the negative battery cable.
  10.  
  11. Fill the fuel tank. Turn the ignition key ON and allow the fuel system to prime.
  12.  
  13. Start the engine and check for leaks.
  14.  

TESTING



  1. Relieve the fuel system pressure as noted earlier in this Section.
  2.  
  3. Disconnect the fuel inlet line at the fuel filter and install a suitable pressure gauge on the line.
  4.  
  5. Either start the engine or jumper the fuel pump relay, using a suitable jumper wire. Check the system pressure on the gauge.
  6.  
  7. With fuel pump relay jumpered, fuel pressure should be 35-43 lbs. With the engine idling fuel pressure should be 25-33 lbs.
  8.  
  9. If the pressure is not within specification, check for restrictions in the fuel lines or replace the in-tank fuel pump.
  10.  
  11. Before removing the pressure gauge, relieve the fuel pressure again.
  12.  
  13. Reconnect the fuel line. Start the engine and check for leaks.
  14.  

 
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