Replacing Fuel Pump In Chevy Corsica: Step-By-Step Guide

Changing the fuel pump on a Chevy Corsica can be a complex task and is best left to professionals. The fuel pump is located inside the fuel tank and can be accessed through an access panel above the tank in the passenger compartment. If there is no access panel, the fuel tank must be drained and lowered from the vehicle to access the pump. The process involves disconnecting the battery, removing the pump and any reusable brackets and pick-up screens, installing a new pump, and reconnecting the hoses and electrical connections. It is important to take precautions to prevent fires when working with the fuel system.

Disconnect the battery

Disconnecting the battery is the first step in changing the fuel pump on a Chevy Corsica. This is a crucial safety measure that must be taken to reduce the chance of a fire. Before you begin, make sure you have the necessary tools and safety equipment, such as gloves and eye protection. Here are some detailed instructions to guide you through the process:

Step 1: Locate the Battery

The battery is usually located in the engine compartment of your Chevy Corsica. Open the hood of your car and identify the battery. It is typically a rectangular unit with two terminals, marked positive (+) and negative (-).

Step 2: Identify the Negative Battery Cable

The negative battery cable is typically black and is connected to the negative terminal of the battery. It is important to identify this cable correctly, as we will only be disconnecting the negative cable in this procedure.

Step 3: Loosen the Negative Battery Cable Clamp

Using an appropriate tool, such as a wrench or socket, loosen the clamp that secures the negative battery cable to the terminal. Be careful not to loosen or remove the positive cable.

Step 4: Disconnect the Negative Battery Cable

Once the clamp is loose, carefully remove the negative battery cable from the terminal. You may need to wiggle it gently to detach it completely. Ensure that the cable does not touch any metal parts of the car to avoid creating a short circuit.

Step 5: Secure the Cable

After disconnecting the cable, make sure to secure it away from the battery and any metal components. You can use a cable tie or a non-conductive material to hold it in place. This step ensures that the cable does not accidentally come into contact with the battery or any metal surfaces during the fuel pump replacement process.

Remember to reconnect the negative battery cable once you have completed the fuel pump replacement. It is important to follow the same safety precautions when reconnecting the battery. Always connect the negative cable last, after all other connections have been made.

Remove the fuel tank

To remove the fuel tank from a Chevy Corsica, you must first relieve the fuel system pressure and disconnect the negative cable from the battery. Drain the fuel tank into an approved container. Raise and safely support the vehicle. Detach the fuel sender electrical connector and remove the muffler hanger bolts. Remove the exhaust rubber hangers and allow the exhaust system to rest on the rear axle. Disconnect the quick-connect hoses from the fuel tank sender and detach the hoses at the tank from the filter vent and vapor pipes. With an assistant, support the fuel tank, then disconnect the two fuel tank retaining straps. Finally, remove the tank from the vehicle.

Remove the fuel pump

To remove the fuel pump from a Chevy Corsica, the first step is to disconnect the battery, reducing the chance of a fire.

For pumps inside the fuel tank, there will usually be an access cover that needs to be removed. With the cover off, the technician can replace the pump and pre-pump filter screen. In some cases, fuel will need to be drained before removing the access panel.

When the pump is outside the tank, the mechanic will disconnect the fuel lines, remove the pump and install the new one.

Install the new fuel pump

To install the new fuel pump, you will need to follow these steps:

Firstly, ensure the fuel pump is tested to confirm it is faulty. Then, if your Chevy Corsica has an access panel above the tank in the passenger compartment, remove this to access the pump. If there is no access panel, you will need to drain the fuel tank and then lower the tank from the vehicle to access the pump.

Once you have access to the pump, remove the fuel pump supply and return hoses, as well as the EVAP system hoses and electrical connections to the pump. Now, you can remove the faulty pump.

Next, attach any reusable brackets and pick-up screens to the new pump and install it. If your Chevy Corsica has an in-line external filter, now is the time to replace it. Reconnect all hoses and electrical connections.

Finally, add fuel to the tank and run the engine to test for leaks.

It is important to note that you should always replace the fuel filter when replacing the fuel pump, unless it has been replaced recently. Additionally, check the fuel tank straps and fasteners for excessive corrosion and replace them if needed. It is also wise to keep the gas tank at least a quarter full to maximize the life of the new fuel pump.

Reattach the fuel tank and battery

Once the new fuel pump has been installed, the fuel tank and battery can be reattached.

First, ensure that the fuel tank is reattached to the body of the car and secured with the retaining straps. Tighten the strap bolts to 24 ft. lbs. (33 Nm).

Next, connect the hoses to the filler, vent, and vapor pipes. Attach the nylon fuel feed and return connecting line quick-connect fittings to the fuel sender.

Then, install the exhaust rubber hangers and the muffler hanger bolts. Tighten the muffler hanger bolts to 11 ft. lbs. (15 Nm).

Finally, attach the fuel tank sender electrical connector and carefully lower the vehicle. Reattach the negative battery cable.

It is important to note that working with the fuel system can be dangerous, so all precautions should be taken to avoid starting a fire. After the repair, be vigilant for any fuel leaks or odors. If you notice any issues, do not start or drive the car, and do not park inside your house or under a covered structure. Instead, have the car towed to a shop for inspection and repair.

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