Here's a general outline. Specific steps and complexities might vary slightly depending on your exact Corsica's trim level and equipment:
1. Preparation:
* Safety First: Disconnect the negative battery terminal. Wear safety glasses and gloves. Work in a well-ventilated area.
* Gather Tools: You'll need jack stands, a jack, socket wrenches (various sizes), a fuel line disconnect tool (important!), a fuel pump pliers or a fuel pump removal tool (if needed), rags, a container to catch fuel, possibly a torque wrench, and the new fuel pump. Consult your repair manual for specific socket sizes.
* Consult a Repair Manual: A Haynes or Chilton repair manual for your specific year and model is highly recommended. It will provide detailed diagrams and instructions specific to your vehicle.
2. Accessing the Fuel Pump:
* Lower the Fuel Tank: This is usually the most challenging part. You'll likely need to:
* Drain the fuel tank: Use a siphon pump to safely remove as much fuel as possible. This reduces the risk of spills and makes the tank lighter.
* Access the fuel tank: This usually involves lowering the fuel tank. This may involve removing the fuel filler neck, disconnecting the fuel lines, and possibly removing the exhaust system (partially or completely). Your repair manual will detail this process. The tank is secured by straps or bolts – carefully loosen and lower it using jacks.
* Locate the Fuel Pump: The fuel pump is usually located within the fuel tank's assembly. It might be accessed through a large access panel on top of the tank or removed entirely with the tank.
3. Replacing the Fuel Pump:
* Disconnect Fuel Lines: Carefully disconnect the fuel lines using your fuel line disconnect tool. These lines are under pressure, so be prepared for a small amount of fuel to escape. Quickly plug the lines to prevent fuel leakage.
* Disconnect Electrical Connectors: Unplug the electrical connectors from the fuel pump.
* Remove the Fuel Pump: This might involve removing retaining clips, bolts, or a retaining ring. Your repair manual will show you how. Some pumps are assembled in a module with the sending unit, so this entire assembly might need replacement.
* Install the New Fuel Pump: Carefully install the new fuel pump, ensuring all seals are correctly seated.
* Reconnect Everything: Reconnect the electrical connectors and fuel lines, making sure everything is securely fastened.
4. Reassembly:
* Raise the Fuel Tank: Carefully raise the fuel tank back into its position.
* Reconnect Everything: Reconnect all fuel lines, electrical connectors, and other components removed during the process.
* Refuel the tank: Carefully fill the tank with fuel.
* Check for Leaks: Check for any fuel leaks around the fuel lines and the fuel pump.
* Reconnect the Battery: Reconnect the negative battery terminal.
5. Testing:
* Start the Engine: Start the engine and let it run for a few minutes. Listen for any unusual noises from the fuel pump.
* Check for Leaks: Inspect again for any leaks.
* Test Drive: Take the car for a test drive to ensure the fuel pump is functioning correctly.
Important Considerations:
* Fuel Pressure: You might want to check the fuel pressure before and after the replacement to ensure the new pump is working correctly. This requires a fuel pressure gauge.
* Fuel System Safety: Work in a safe and well-ventilated area, away from any open flames or sparks.
* Professional Help: If you're not comfortable with this task, it's best to take your car to a qualified mechanic. Improperly installing a fuel pump can lead to serious safety issues.
This is a general guide. Always consult a repair manual specific to your 1990 Chevy Corsica to get detailed instructions and diagrams. The exact procedure may vary slightly depending on the specific model and options. Safety should be your top priority throughout this process.
