Here's a general outline of how to replace the fuel pump on a 1992 Geo Prizm 1.6L. However, this is a complex job with safety implications. If you're not comfortable working with fuel systems, I strongly recommend taking it to a qualified mechanic. Working with gasoline is extremely dangerous.
Safety Precautions are paramount:
* Disconnect the negative battery terminal before starting any work.
* Work in a well-ventilated area. Gasoline fumes are highly flammable and toxic.
* Never smoke or have any open flames near the fuel system.
* Use appropriate safety glasses and gloves.
* Have a fire extinguisher readily available.
* Consider using a fuel pump removal tool which helps simplify removing the pump assembly.
Steps (General Outline - consult a repair manual for your specific model):
1. Prepare the Vehicle: Jack up the car securely and support it with jack stands. Locate the fuel tank access panel (usually under the car, near the rear axle).
2. Disconnect Fuel Lines: Carefully release the pressure in the fuel system. This usually involves running the engine until it stalls, but consult a repair manual for the specific procedure. Then disconnect the fuel lines from the fuel tank. Have some rags handy to soak up any spilled fuel. Mark the fuel lines carefully to ensure correct reassembly.
3. Disconnect Electrical Connections: Disconnect the electrical connector to the fuel pump.
4. Lower the Fuel Tank: Locate the fuel tank straps and carefully remove them. You may need to disconnect other components to provide enough clearance to lower the tank. Use a fuel tank support to help prevent the tank from dropping too far.
5. Access the Fuel Pump: Once the tank is lowered, you'll usually find an access panel on the top of the tank. Remove this panel to access the fuel pump assembly.
6. Remove the Fuel Pump Assembly: This typically involves disconnecting several parts including the fuel level sender. Use the correct tools and take pictures as you disassemble to aid in reassembly.
7. Install the New Fuel Pump: Install the new fuel pump assembly, ensuring everything is properly seated and connected.
8. Reassemble: Raise the fuel tank and re-secure it. Reconnect the fuel lines, electrical connections, and any other components you disconnected. Double-check all connections.
9. Bleed the Fuel System: You'll likely need to prime the fuel system to get the engine running again. This might involve turning the ignition key several times or using a manual priming tool. Consult your repair manual for the proper bleeding procedure.
10. Check for Leaks: Carefully inspect all connections for leaks before starting the engine.
Strongly Recommended Resources:
* A repair manual specifically for your 1992 Geo Prizm 1.6L: This will provide detailed diagrams, step-by-step instructions, and torque specifications. Haynes and Chilton manuals are popular options.
* A YouTube video showing the fuel pump replacement for a similar year/model: While not a replacement for a repair manual, videos can be helpful in visualizing the process.
Remember, safety is paramount. If you're unsure about any step, don't hesitate to seek professional help. Improper fuel system repair can lead to serious injury or fire.
