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1992 Geo Metro replacing the Fuel Pump


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elevator
02-24-2006, 09:33 PM
Stop where you are. Before you replace the Fuel Pump, make sure that the FUEL PUMP RELAY is OK.

The FUEL PUMP RELAY is located in a black fuse box in the engine compartment above the drivers front tire. The RELAY is black and measures about 2 inches tall, 1 inch wide and 1 inch deep. Its about $51, but it takes 1 to 8 days to get one cause no one has it in stock.

The Metro's fuel pump does not give any electrical motor noise when I turn the ignition on. I unplugged the fuel line from the carburator and it was dry even after I turned the engine for a minute.
Because of what I have read on this forum, I am about to replace the fuel pump with a new one. I will post the procedure and maybe some pics while I do it.

Using a 5 ton jack, I lifted the Metro and put it on some jack stands. The metro sits up high now, so I can crawl under easily. I opened the gas cap door and removed three screws, releasing the gas tank hose from the body of the metro.

I removed the screws holding the gas tank on the the underbody of the Metro and tried to lower the tank, to access the fuel pump, but the muffler pipe was blocking the way, so I seperated the pipe from the catalytic converter and push it towards the front of the Metro, which gave me the room necessary to lower the tank. I placed a bath towel on the jack under the tank and tried to lower it, but there is a small bracket holding two 3/8 metal pipes attached to the tank. I have tried to remove the bolt from underneath but have found it difficult to do so. I guess its time to take a break.
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Turns out the bolt is welded, so I poked a hole under the car with a long screwdriver, which came out under the rear seat. While inside the car, I put the screwdriver into the hole I made under the seat and
reached the screw. The screw came right off and the gas tank was free at last.

Using my orange jack, I lowered the tank and replaced the pump. There were a bunch of hoses that had to be disconnected, because the teeth on the hose clamps were rather wide, I had to buy a wide tooth vice-grip pliers. I used a small vice-grips to grip a phillips screwdriver tip to remove the many screws holding down the fuel pump in place.

Replacing the fuel filter was a real job, There is a screw with a 10mm head that releases the filter clamp. By the way only remove the hose clamps attached to the filter.

I cound not find the wiring under the seat untill I had finish putting everything back together.

Feel free to ask me about this project.

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