Metro, Prizm 2000-2002

Fuel Pump

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the fuel tank by pumping the fuel out through the filler neck into a suitable container.
  6.  
  7. Remove or disconnect the following:

    Rear seat cushion
     
    Fuel pump electrical connector
     
    Muffler and exhaust pipe assembly
     
    Fuel filler hose
     
    Fuel feed and return clamps and hoses from the pump
     
    Fuel tank from the vehicle
     
    Screws from the pump assembly
     
    Fuel sender assembly
     

  8.  
  9. Disassemble the fuel sending unit by removing or disconnecting the following:

    Fuel level sensor by depressing the tab
     
    Lower assembly end cap
     
    Fuel pump cushion
     
    Fuel sender sub assembly electrical connectors
     
    Fuel pump from the sender assembly
     
    Fuel tube and 2 grommets from the fuel sender sub assembly
     

  10.  
  11. The sender sub assembly contains the fuel filter and must be serviced as an assembly.
  12.  

To install:

  1. Install or connect the following:

    Fuel tube and 2 new grommets from the fuel sender sub assembly
     
    Fuel pump to the sender assembly
     
    Fuel sender sub assembly electrical connectors
     
    New fuel pump cushion
     
    Lower assembly end cap
     
    Fuel level sensor
     
    Fuel sender assembly with a new gasket in the fuel tank and torque the screws to 89 inch lbs. (10 Nm)
     
    Fuel feed and return hoses and clamps on the fuel pump
     
    Fuel sender electrical connectors
     
    Fuel tank and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Fuel filler hose
     
    Muffler and exhaust pipe assembly and torque the bolts to 26 ft. lbs. (35 Nm)
     
    Rear seat cushion
     
    Negative battery cable
     

  2.  
  3. Refill the fuel tank.
  4.  
  5. Turn the ignition key ON and allow the fuel system to pressurize.
  6.  
  7. Start the engine and check for leaks, repair if necessary.
  8.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the fuel tank into a suitable container.
  6.  
  7. Remove or disconnect the following:

    Rear seat cushion to gain access to the service panel
     
    Access panel
     
    Fuel sender electrical connectors
     
    Fuel line retaining clip
     
    Fuel line
     
    Fuel sender from the tank
     

  8.  
  9. Disassemble the Fuel sender assembly by removing or disconnecting the following:

    End cap
     
    Fuel pressure regulator
     
    Fuel pump strainer retaining clip
     
    Fuel pump strainer
     
    Fuel sender assembly housing from the fuel level sensor and gauge unit
     
    Fuel pump electrical connector
     
    Fuel pump from the fuel filter
     
    Fuel filter from the fuel level sensor and gauge unit

    Click image to see an enlarged view

    Fig. Remove the fuel pump and the sender assembly from the fuel tank slowly to keep from splashing fuel-Prizm



    Click image to see an enlarged view

    Fig. Exploded view of the fuel sender assembly unit

     

  10.  

To install:

  1. Install or connect the following:

    New fuel filter to the fuel level sensor and gauge unit
     
    Fuel pump into the fuel filter
     
    Fuel pump electrical connector
     
    Fuel pump assembly to the fuel level sensor and gauge unit
     
    Fuel pressure regulator
     
    Fuel pump strainer
     
    End cap
     
    Fuel sender assembly to the tank using a new gasket and torque the bolts to 35 inch lbs. (4 Nm)
     
    Fuel line and retaining clip
     
    Fuel sender electrical connector
     
    Negative battery cable
     

  2.  
  3. Refill the fuel tank.
  4.  
  5. Turn the ignition ON to pressurize the fuel system.
  6.  
  7. Check for fuel leaks and repair if necessary.
  8.  
  9. Install the service access panel and rear seat cushion.
  10.  

 
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