How to Change a Fuel Pump on a 2002 Pontiac Grand Amby Eric Grosso
Replacing the fuel pump on a 2002 Pontiac Grand AM can be done with a set of hand tools, a vehicle jack and a set of jack stands. Doing the repair yourself can save hundreds of dollars in repair bills.
Having previous automotive repair experience aids greatly in this process, however, it can be done by a careful and precise novice mechanic.
Raise the rear of the vehicle with a vehicle jack and place two jack stands underneath the vehicle so the car is secure. Remove the vehicle jack.
Remove the negative battery cable from the battery terminal.
Relieve the fuel system pressure by removing the fuel tank cap. Locate the fuel pressure port at the end of the fuel rail--it is covered by a black twist-off cap. Remove the cap and place towels around the end of the rail. Touch the port with a small tool to eliminate any pressure in the system. Replace the cap when finished, relieving the pressure.
Remove the Fuel Tank
Disconnect the bolts holding the exhaust to the vehicle as well as the rubber insulators and bring the exhaust down to sit on the rear axle.
Remove the fuel lines from the fuel tank as well as the line connected to the evaporative emissions control (EVAP) canister.
Remove the electrical connectors that connect the fuel pump to the fuel tank.
Disconnect the filler tube from the fuel tank by loosening the hose clamps.
Disconnect the fuel tank straps by removing the strap bolts. Once the straps are disconnected, the fuel tank can be removed.
Removing the Fuel Pump
Disconnect the connectors from the wiring harness.
Remove the wiring harness from the top of the fuel pump and set aside.
Remove the seal between the tank and the pump.
Remove the fuel pump.
Remove the fuel-sending unit and pressure sensor from the old unit. Clean the surface where the fuel pump connects to the fuel tank.
Installing a New Fuel Pump
Connect the fuel-sending unit and pressure sensor onto the new fuel pump.
Install a new O-ring seal onto the new fuel pump and install the new fuel pump into the tank. Make sure to align the small notch in the fuel tank with the tab on the new fuel pump. Connect the wiring harness to the fuel pump.
Replace the fuel tank by lifting the tank up and fastening the strap bolts.
Reattach the filler tube to the fuel tank and tighten the hose clamps.
Reconnect the fuel lines and the reconnect the line attached to the EVAP canister.
Lift the exhaust, place the rubber insulators and fasten the exhaust bolts.
- When removing the fuel tank, many mechanics choose to either wait until a small amount of gas is left in the tank or siphon the fuel from the tank.
Items you will need
- Vehicle jack
- Jack stands
- Socket set
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