GM Metro/Sprint 1985-1993 Repair Guide

Electric Fuel Pump

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REMOVAL & INSTALLATION



See Figures 1 and 2



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



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Fig. Fig. 2: Fuel filter assembly

  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 12 attaching screws from the fuel pump assembly and remove the assembly with the gasket from the fuel tank.
  14.  
  15. Remove the 1 mounting screw from the fuel pump motor assembly. Remove the 2 fuel pump motor connectors and remove the fuel pump motor from the fuel pump assembly.
  16.  

To install:
  1. Install the 2 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 12 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 fuel system pressure.
  2.  
  3. Disconnect the fuel inlet line at the fuel filter and install a suitable pressure gauge on the line.
  4.  
  5. Connect a jumper wire between the terminals of the fuel pump relay connector and check the system pressure on the gauge.
  6.  
  7. Fuel pressure should be 25-33 lbs.
  8.  
  9. As the pressure reaches 33 lbs., the relief valve in the pump should pulsate the pressure so it is always within specification.
  10.  
  11. If the pressure is above specification, check for restrictions in the fuel lines. If no restrictions are found, replace the fuel pump. If the pressure is below specifications, check for battery voltage to the fuel pump and correct as required. If battery voltage is found, replace the fuel pump or fuel pump relay.
  12.  
  13. Before removing the pressure gauge, relieve the fuel pressure again.
  14.  
  15. Reconnect the fuel line. Start the engine and check for leaks.
  16.  

 
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