GM Prizm/Nova 1985-1993 Repair Guide

REMOVAL & INSTALLATION

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1985-92

Before removing fuel system parts, clean them with a spray-type engine cleaner. Follow the instructions on the cleaner. Do not soak fuel system parts in liquid cleaning solvent.


CAUTION
The fuel injection system is under pressure. Release pressure slowly and contain spillage. Observe no smoking/no open flame precautions. Have a Class B-C (dry powder) fire extinguisher within arm's reach at all times.

  1. Remove the filler cap.
  2.  
  3. Using a siphon or pump, drain the fuel from the tank and store it in a proper metal container with a tight cap.
  4.  
  5. Remove the rear seat cushion to gain access to the electrical wiring.
  6.  
  7. Disconnect the fuel pump and sending unit wiring at the connector.
  8.  
  9. Raise the vehicle and safely support it on jackstands.
  10.  
  11. Loosen the clamp and remove the filler neck and overflow pipe from the tank.
  12.  
  13. Remove the supply hose from the tank. Wrap a rag around the fitting to collect escaping fuel. Disconnect the breather hose from the tank, again using a rag to control spillage.
  14.  
  15. Cover or plug the end of each disconnected line to keep dirt out and fuel in.
  16.  
  17. Support the fuel tank with a floor jack or transmission jack. Use a broad piece of wood to distribute the load. Be careful not to deform the bottom of the tank.
  18.  
  19. Remove the fuel tank support strap bolts.
  20.  
  21. Swing the straps away from the tank and lower the jack. Balance the tank with your other hand or have a helper assist you. The tank is bulky and may have some fuel left in it. If its balance changes suddenly, the tank may fall.
  22.  
  23. Remove the fuel filler pipe extension, the breather pipe assembly and the sending unit assembly. Keep these items in a clean, protected area away from the car.
  24.  
  25. While the tank is out and disassembled, inspect it for any signs of rust, leakage or metal damage. If any problem is found, replace the tank. Clean the inside of the tank with water and a light detergent and rinse the tank thoroughly several times.
  26.  
  27. Inspect all of the lines, hoses and fittings for any sign of corrosion, wear or damage to the surfaces. Check the pump outlet hose and the filter for restrictions.
  28.  

To install:
  1. When reassembling, ALWAYS replace the sealing gaskets with new ones. Also replace any rubber parts showing any sign of deterioration.
  2.  
  3. Connect the breather pipe assembly and the filler pipe extension.
  4.  

Tighten the breather pipe screw to 17 inch lbs. and all other attaching screws to 30 inch lbs.

  1. Place the fuel tank on the jack and elevate it into place within the car. Attach the straps and install the strap bolts, tightening them to 29 ft. lbs.
  2.  
  3. Connect the breather hose to the tank pipe, the return hose to the tank pipe and the supply hose to its tank pipe. Tighten the supply hose fitting to 21 ft. lbs.
  4.  
  5. Connect the filler neck and overflow pipe to the tank. Make sure the clamps are properly seated and secure.
  6.  
  7. Lower the vehicle to the ground.
  8.  
  9. Connect the pump and sending unit electrical connectors to the harness.
  10.  
  11. Install the rear seat cushion.
  12.  
  13. Using a funnel, pour the fuel that was drained from its container into the fuel filler.
  14.  
  15. Install the fuel filler cap.
  16.  
  17. Start the engine and check carefully for any sign of leakage around the tank and lines.
  18.  

1993
  1. Relieve the fuel system pressure as outlined earlier in this section.
  2.  
  3. Drain the fuel tank.
  4.  
  5. Remove the rear seat cushion, as outlined in Routine Maintenance 0 .
  6.  
  7. Remove the 4 screws and service hole cover.
  8.  
  9. Remove the fuel sender assembly electrical connector. Raise and suitably support the vehicle.
  10.  
  11. Remove the 2 bolts, the 2 nuts and resonator intermediate pipe assembly from the 3 way catalytic converter (TWC).
  12.  
  13. Remove the 2 bolts and resonator intermediate pipe assembly from the muffler assembly.
  14.  
  15. Remove the 3 bolts and exhaust heat shield from underbody.
  16.  
  17. Remove the 2 bolts and the parking brake cables from underbody.
  18.  
  19. Remove 1 bolt, 1 clamp and fuel filler hose from fuel tank.
  20.  
  21. Remove 1 bolt, 1 clamp and fuel breather hose from fuel tank.
  22.  
  23. Remove 1 nut and fuel feed hose from fuel feed pipe.
  24.  
  25. Remove 1 clamp and fuel return hose from the fuel return pipe at fuel tank.
  26.  
  27. Remove 1 clamp and fuel vapor hose from the fuel vapor pipe at fuel tank.
  28.  
  29. Remove 4 bolts and fuel tank from vehicle.
  30.  
  31. Disassemble 8 bolts and fuel sender assembly from the fuel tank.
  32.  
  33. Disassemble 1 clamp, fuel vapor hose and fuel tank vent valve from fuel tank.
  34.  

To install:
  1. Assemble 1 clamp, fuel vapor hose and fuel tank vent valve to the fuel tank.
  2.  
  3. Install the fuel sender assembly to the fuel tank and tighten the 8 bolts to 89 inch lbs. (10 Nm).
  4.  
  5. Install the fuel tank to the vehicle and tighten the 4 bolts to 22 ft. lbs. (30 Nm).
  6.  
  7. Install the 1 clamp and the fuel vapor hose to the fuel vapor pipe at fuel tank.
  8.  
  9. Install the 1 clamp and the fuel return hose to the fuel return pipe at fuel tank.
  10.  
  11. Install the fuel feed hose to fuel feed pipe and tighten the 1 nut to 15 ft. lbs. (20 Nm).
  12.  
  13. Install the fuel breather hose to the fuel tank and install the clamp. Tighten the bolt to 15 ft. lbs. (20 Nm).
  14.  
  15. Install the fuel filler hose to the fuel tank and install the clamp. Tighten the bolt to 15 ft. lbs. (20 Nm).
  16.  
  17. Install the parking brake cables to the underbody and tighten the 2 bolts to 22 ft. lbs. (30 Nm).
  18.  
  19. Install the exhaust heat shield to the underbody and tighten the 3 bolts to 48 inch lbs. (5.4 Nm).
  20.  
  21. Install the bolts and resonator intermediate pipe assembly to the muffler assembly and tighten the 2 bolts to 14 f. ft. lbs. (19 Nm).
  22.  
  23. Install the resonator intermediate pipe assembly to the 3 way catalytic converter (TWC) and tighten the 2 bolts and 2 nuts to 32 ft. lbs. (43 Nm).
  24.  
  25. Lower the vehicle.
  26.  

 
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