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HOMESERVICE MANUALSCHEVROLET1993CAVALIER VL, 4D WAGONREPAIR AND DIAGNOSIS (SINGLE PAGE)ENGINE PERFORMANCESYSTEMENGINE CONTROLS - BASIC TESTINGBASIC FUEL SYSTEM CHECKS (A-7)FUEL SYSTEM PRESSURE TEST (EXCEPT SATURN)FUEL PRESSURE CHECK (TBI)
1993 Chevrolet Cavalier VL, 4D Wagon

Fuel Pressure Check (TBI)

1993 Chevrolet Cavalier VL, 4D WagonSECTION Fuel Pressure Check (TBI)
  1. Remove air cleaner, and plug thermal vacuum port on throttle body. After shutting off engine, wait at least 2 minutes before connecting fuel pressure gauge. When removing fuel line, always use 2 wrenches. Install Fuel Pressure Gauge (J-29658B or BT-8205) and Adapter (J-29658-85) in fuel line between steel line and flexible hose.
  2. Turn ignition on and observe fuel pressure reading. Fuel pressure should read 9-13 psi (.6-.9 kg/cm2 ). If no fuel pressure is indicated, go to step 5). If fuel pressure is okay but engine will not start, go to NO START DIAGNOSIS. If fuel pressure is present but is too high, go to step 4). If fuel pressure is present but is too low, gradually pinch off fuel return line to fuel tank.
    NOTE: It should not be necessary to completely restrict fuel return line to observe a pressure increase. DO NOT damage return line.
  3. If fuel pressure remains low, check for plugged fuel filter or restriction in fuel delivery line. If filter is okay and no restrictions are present, replace fuel pump. If fuel pressure increases when return line is pinched, replace fuel pressure regulator.
  4. If fuel pressure is present but is higher than specification, check for restriction in fuel return line. If return line is not restricted, replace fuel pressure regulator.
  5. If no fuel pressure is observed, turn ignition off. Apply battery voltage to fuel pump test connector using a 10-amp fused jumper wire. For location of fuel pump test connector, see COMPONENT LOCATIONS in I - SYS/COMP TESTS article in the ENGINE PERFORMANCE Section. Observe fuel pressure reading. If fuel pressure is still not evident, check wiring between test connector and fuel pump. If wiring is okay, replace fuel pump.
  6. If fuel pressure is present with voltage applied to test connector, test fuel pump relay and voltage supply to relay. See I - SYS/COMP TESTS article in the ENGINE PERFORMANCE Section.
  7. After all repairs, allow fuel pressure to dissipate. Remove fuel pressure gauge, and reconnect fuel line. Start engine and watch for fuel system leaks. For further details on fuel pressure testing, see I - SYS/COMP TESTS article in the ENGINE PERFORMANCE Section.
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.