Testing the fuel pump pressure with a fuel pressure test gauge isn't difficult on the 2.2L Chevrolet Cavalier, Beretta, Corsica, and 2.2L Pontiac Sunfire.
In this tutorial, I'll explain how to perform the fuel pump pressure test with a fuel pressure test gauge step by step.
You'll quickly find out if a fuel pump issue is causing an engine no-start or performance problem.
Contents of this tutorial:
You can find this tutorial in Spanish here: Cómo Probar La Bomba De Combustible (1992-1997 2.2L Beretta, Cavalier, Corsica, Sunfire) (at: autotecnico-online.com).
APPLIES TO: This tutorial applies to the following vehicles:
- 2.2L Chevrolet Beretta: 1992, 1993, 1994, 1995, 1996.
- 2.2L Chevrolet Cavalier: 1992, 1993, 1994, 1995, 1996, 1997.
- 2.2L Chevrolet Corsica: 1992, 1993, 1994, 1995, 1996.
- 2.2L Pontiac Sunfire: 1995, 1996, 1997.
Symptoms Of A Bad Fuel Pump
It's been my experience over the years that fuel pump failures usually come in one of two flavors:
- The engine does not start.
- The engine starts and runs, but runs very badly.
When the fuel pump supplies barely enough fuel to start the engine, you'll see one or more of the following symptoms:
- Engine takes longer than usual to start (extended cranking).
- Engine idle is very rough.
- Engine backfires thru' the intake manifold under load.
- Engine starts, then dies.
Both can be diagnosed with a simple fuel pump pressure test.
Where To Buy A Fuel Pressure Test Gauge
The following fuel pressure test kit has the quick disconnect adapter you need to test the fuel pump's performance.
I also include a link to the quick disconnect tools you'll need to disconnect the fuel line to connect the fuel pressure tester's quick-disconnect adapter.
Fuel Pump Pressure Specification
| Chevrolet | ||
|---|---|---|
| Year/Engine/Model | KOEO | KOER |
| 1992-1996 2.2L Beretta | 40-47 PSI | should drop 3 to 10 PSI* |
| 1992-1997 2.2L Cavalier | 40-47 PSI | should drop 3 to 10 PSI* |
| 1992-1996 2.2L Corsica | 40-47 PSI | should drop 3 to 10 PSI* |
* With vacuum hose connected to fuel pressure regulator.
| Pontiac | ||
|---|---|---|
| Year/Engine/Model | KOEO | KOER |
| 1995-1997 2.2L Sunfire | 40-47 PSI | should drop 3 to 10 PSI* |
* With vacuum hose connected to fuel pressure regulator.
KOEO = Key On Engine Off.
KOER = Key On Engine Running.
Using A Fuel Pump Pressure Tester To Test The Fuel Pump
To test the fuel pump's pressure, you'll connect a special fuel pressure tester adapter between the input fuel pressure line and the fuel injector rail.
In photo 1 of 3, I've identified the input fuel pressure line (you'll need to disconnect) with an orange arrow.
Once the adapter (called a quick disconnect adapter) is in place, you'll connect the fuel pressure test gauge to it (see photo 2 of 3 to see an example of the adapter).
The fuel pump pressure specification for the models covered by this tutorial is:
- 40-47 PSI Key On With Engine Off.
- With Key On Engine Running, fuel pressure should drop 3 to 10 PSI.
NOTE: If you don't have a fuel pressure tester with the correct adapter or don't have the quick disconnect tool, see my recommendations here: Where To Buy A Fuel Pressure Test Gauge.
OK, let's get this show on the road:
- 1
Place a shop towel around the fuel pressure line (where it connects to the fuel injector rail). The shop towel's job is to absorb any fuel that may leak when doing step 2.
- 2
Disconnect the fuel pressure line from the fuel injector rail.
NOTE: You'll need to use a quick-disconnect tool to disconnect the fuel pressure line from the fuel injector rail. - 3
Connect the test adapter between the fuel pressure line and the fuel injector rail.
- 4
Connect the fuel pressure gauge to the adapter.
- 5
When ready, ask your helper to cycle the key ON and OFF but don't crank the engine.
- 6
Check your connections for fuel leaks. Resolve any fuel leaks before continuing to the next step.
- 7
Crank the engine and check the fuel pressure gauge.
- 8
Your fuel pressure gauge should register the specified fuel pressure.
Let's interpret your test results:
CASE 1: The fuel pressure test gauge registered 0 PSI. This test result confirms that a lack of fuel from the fuel pump is causing the engine to not start.
This test result usually confirms that the fuel pump has failed and needs to be replaced. When replacing the fuel pump, you'll also need to replace the fuel pump strainer and the fuel filter.
CASE 2: The fuel pressure gauge registered the indicated fuel pressure specification. This test result tells you that the fuel pump is functioning correctly and sending fuel to the fuel injectors.
If the engine isn't starting, You can conclude that the fuel pump IS NOT behind the issue.
CASE 3: The fuel pressure gauge registered a fuel pressure way below the specification. This test result tells you that the fuel pump is failing. Replace the fuel pump, the fuel pump strainer, and the fuel filter.
