How to Change a Fuel Pump on a 2002 Pontiac Cars

by Contributing Writer; Updated June 12, 2017

Imagine that you have just finished filling the gas tank of your bright red Pontiac car and a few minutes after leaving the station your car sputters and shuts off as if it were out of gas. You hop out and look for leaking gasoline, but there is none to be found. You probably need to replace the fuel pump. The fuel pump moves the fuel from your tank to the engine, and when it stops working your car will shut off, as if it is out of gas. Learn how to remove a faulty fuel pump and you can avoid costly trips to the local mechanic.

Under The Hood:

 How to Change a Fuel Pump on a 2002 Pontiac Grand Am

Preparation

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.

Items you will need

  • Towels

  • Vehicle jack

  • Jack stands

  • Pliers

  • Screwdriver

  • Socket set

 How to Change the Fuel Pump in a 2003 Pontiac Grand Am

Remove the negative battery cable from the battery.

Siphon the fuel out of the tank using the siphoning kit.

Raise the rear of the vehicle with the hydraulic vehicle jack and support the rear of the car with jack stands, checking to make sure the car is secure in the stands before removing the hydraulic jack.

Remove the fuel tank gas cap.

Located the fuel system pressure port. It can be found on the side of the fuel rail or near the front of the car in a fuel line, covered by a black cap. Remove the cap. Surround the port with rags and put pressure on the port, relieving pressure from the fuel system. Replace the cap.

Remove the rear exhaust so you can access the gas tank. After removing the exhaust bolts, you can move the exhaust system to the side, resting it on the rear axle instead of completely removing it.

Disconnect the line running from the fuel tank to the EVAP canister, a small, black canister near the fuel tank.

Disconnect the fuel return and feed lines going into the gas tank.

Loosen the hose clamp connecting the fuel filler tube to the fuel tank and remove the tube from the tank.

Remove the fuel tank and pump module by loosening the two bolts holding in each strap. After the straps are removed, the fuel tank can be dropped.

Disconnect all electrical connectors from the fuel pump running to the fuel tank.

Pull away the retaining ring using the pliers and remove the fuel pump module.

Remove the fuel pressure sensor and sending unit from the old pump module and attach them to the new module.

Install the new module into the fuel tank using a new O-ring.

Connecting all electrical connections from the fuel tank to the new pump module.

Connect the filler tube back to the fuel tank and tighten the clamp.

Connect the fuel feed and return lines and the hose running from the fuel tank to the EVAP canister.

Replace the rear exhaust.

Lower the vehicle from the jack stands using the hydraulic jack.

Reconnect the negative battery cable.

Items you will need

  • Pliers

  • Siphon kit

  • Rags

  • Hydraulic car jack

  • Jack stands

  • Screwdriver

  • Socket set

 How to Replace a Fuel Pump in a 1999 Pontiac Bonneville

Removing the Fuel Pump

Loosen the fuel-tank filler cap and open the hood.

Remove the fuel-injector shield, if your Bonneville model is equipped with it, using a ratchet and socket.

Disconnect the ground (black) battery cable using a wrench.

Wrap a shop towel around the fuel pressure connection fitting. This is a small valve on the fuel rail, where the fuel injectors attach, that resembles the air valve on your car tires.

Depress the valve with a screwdriver as you catch the squirt of fuel coming out of the valve with the shop towel. This will release the pressure in the fuel system.

Raise the rear of your Bonneville using a floor jack and place it on jack stands.

Chock the front wheels.

Put on your goggles, get under the vehicle and support the fuel tank with the floor jack. Place a small wood block between the jack’s saddle and the fuel tank to prevent damage to the tank.

Disconnect the rubber hangers holding the exhaust system in place on the rear of the vehicle to gain better access to the fuel tank. Use a screwdriver and a pair of needle-nose pliers.

Unfasten the two bolts from the straps holding the fuel tank in place. Use a ratchet, ratchet extension and socket.

Lower the fuel tank just enough to gain access to the hose connectors on the fuel-tank gauge sender and pump assembly.

Disconnect the hoses and unplug the electrical connector from the fuel-tank gauge sender and pump assembly. On hoses with plastic connectors, press the two tabs on the hose fittings and separate the hoses. On hoses with metal fittings use special tool J-37088-A to disconnect the lines.

Lower the tank and unlock the gauge sender and pump assembly from the fuel tank by turning the locking ring counterclockwise with tool J-24187 or similar spanner wrench.

Pull the gauge sender and pump assembly out of the tank and discard the O-ring seal on the assembly.

Disconnect the holding clamps, hoses and electrical connectors attached to the fuel pump and remove the pump from the assembly.

Installing the New Fuel Pump

Place the new pump on the assembly and connect the hoses.

Install the gauge sender and pump assembly in the tank along with a new O-ring seal.

Lock the gauge sender and pump assembly to the fuel tank by turning the locking ring clockwise using tool J-24187 or similar spanner wrench.

Raise the fuel tank just enough to connect the hoses and plug the electrical connector to the fuel-tank gauge sender and pump assembly.

Raise the fuel tank in position and secure the two holding straps using the ratchet, ratchet extension and socket.

Remove the floor jack from under the vehicle.

Connect the rubber hangers to the exhaust system if you had to disconnect it. Use the screwdriver and the needle-nose pliers.

Lower your vehicle.

Tighten the fuel-filler cap.

Connect the ground (black) battery cable using the wrench.

Turn the ignition switch to the “On” position for three seconds. Turn it off and then on again and check for leaks under the fuel tank.

Turn off the ignition.

Items you will need

  • Ratchet

  • Socket

  • Wrench

  • Shop towel

  • Screwdriver

  • Floor jack

  • 2 jack stands

  • Chocks

  • Goggles

  • Wood block

  • Needle-nose pliers

  • Ratchet extension

  • Special tool J-37088-A

  • Special tool J-24187

  • New O-ring seal

 How to Replace the Fuel Pump on a Firebird

Relieve the pressure in the fuel system. Open the gas cap, go to the fuse box within the engine and remove the fuse for the fuel system. Start the engine and let it run until it stops. Disconnect the negative battery cable.

Raise the car on jack stands and drain the fuel from the tank. Remove the tank's drain plug or the line running to the fuel filter. Make sure you know how much fuel is in the tank and have an approved container to pour it into.

Clean the fuel system's exterior, especially around the fuel-sender assembly. This will prevent anything from contaminating the fuel system upon disassembly.

Disconnect and remove the fuel tank and sender assembly from the fuel pump. Disconnect the fuel sender from the tank by removing its retaining ring and remove the pump from the sender.

Install the new fuel pump onto the fuel sender and attach the sender back to the tank. Use a new strainer with the new pump and new O-rings on the tank's opening groove and the sender feed tube. Fold the strainer over itself and place the sender in the tank carefully so the strainer isn't damaged or trapped by the sump walls.

Reconnect the fuel tank, torquing its bolts to 33 foot pounds. Refill the tank, close the fuel cap and reconnect the fuel system's fuse and the battery cable.

Turn the ignition switch on (without starting the Firebird) for two seconds, switch it back off for 10 seconds and switch it back on. Repeat this two to three times to restore pressure in the system and check for leaks.

Items you will need

  • Fuel pump Large gas can Wrench Fuel-pump strainer O-rings Jack stand

 How to Replace a Fuel Pump in a Pontiac Grand Am

Choose a new fuel pump for your Pontiac Grand Am. This will require you to know the make and model, engine size and engine type. Models made from 1973 to 1975 may have a 6.5 L or 7.4 L engine. The next generation of the Pontiac Grand Am was made from 1985 to 1991 and was equipped with 2.3 L, 2.4 L, 2.5 L and 3.0 L engines.

Look at more recent versions of the Grand Am. Models made from 1992 to 1998 may have a 2.3 L, 2.4 L, 3.1 L or 3.3 L engine. The latest generation of the Pontiac Grand Am was made from 1999 to 2005 and may have a 2.2 L, 2.4 L or 3.4 L engine.

Prepare your vehicle for fuel pump servicing. Relieve the fuel system pressure and drain the fuel tank.

Release the snap ring by holding the fuel sender assembly down, or remove the cam lock ring with tool J39765, depending on the model. You will now be able to remove the fuel sender and fuel strainer.

Disconnect the connector retainer for the fuel pump wiring harness. Release the three tabs on the fuel sender beginning with the tab opposite the fuel level sensor and move clockwise.

Lift the cover assembly to disconnect the fuel pump electrical connection and rotate the fuel pump baffle counterclockwise to remove it. Slide the fuel pump outlet out of the slot by sliding it out of the slot and discard the seal.

Install the new fuel pump using the items included in the kit, especially the new seal. Complete the installation by reversing the removal procedure.

Items you will need

  • Fuel pump kit

  • Tool J39765

 How to Replace a Fuel Pump in a Pontiac Bonneville

Select the new fuel pump for your Pontiac Bonneville. You will not only need to know the make and model, but also the engine size. Models made from 1958 to 1964 have a 389 cubic inch (ci), 400ci or 421ci engines. Models built from 1965 to 1970 also have the option of a 428ci or 455ci engine. Models made from 1971 to 1976 are limited to 400ci or 455ci engines.

Look at later generations of the Pontiac Bonneville. Models made from 1977 to 1981 have 231ci, 265ci, 301ci, 350ci or 400ci engines. Options for 1982 to 1986 include a 231ci, 305ci, 2.8L, 4.3L or 350ci diesel engine, and 1987 to 1999 models have a 3.8L engine.

Examine the last generation of the Pontiac Bonneville. These models were made from 2000 to 2005 and were available with a 3.8 L or 4.6 L engine.

Prepare your vehicle for fuel pump servicing. Relieve the fuel system pressure and drain the fuel tank. Disconnect the negative battery cable with a socket wrench. Remove the jack and spare tire so that you can remove the lining in the trunk. This will allow you to open the fuel sender access panel.

Remove the quick connect fittings and electrical connector from the fuel sender. Remove the retaining ring for the fuel sender and take note of the position of the fuel sender before removing it. Discard the O-ring.

Note the position of the strainer before you remove it. Unplug the electrical connections and hoses from the fuel pump. Take out the fuel pump.

Install the new fuel pump using the old grommets and insulators, but replace the O-ring and strainer. Complete the installation by reversing the removal procedure.

Items you will need

  • Fuel pump kit

  • Socket wrench

 How to Replace the Fuel Pump in a Fiero

Removing the Fuel Pump

Remove the wire connected to the negative battery terminal. The negative wire will usually be black in color and the terminal often has a minus sign.

Continue to Step 2 if your engine's fuel injection type is throttle body injection. Usually, V4 Fiero engines are this type.

Skip to Step 3 if your engine is of the multi-fuel injection variety. Usually, V6 Fiero engines are this type.

Pull the fuel pump fuse out of your fuseblock.

Start your car and run it until it shuts off. This will happen after the gas in the fuel line has been depleted. Attempt to restart it to make certain the fuel is gone. Check that the ignition is in the off position and reset the fuel pump fuse. Continue to Step 4.

Locate the fuel rail on top of the engine. Attach your fuel pressure gauge to the fuel rail valve. Wrap a rag around the fitting while you attach the gauge. Set the bleed hose of your gauge in to a gasoline-safe container. Open the valve and allow the gas to bleed from the fuel line. After the fuel has bled out, remove the gauge and cycle the ignition several times, with 10 seconds in between each cycle. After cycling the ignition, check for any leaks.

Lock the front tires of your vehicle in place with blocks. Initialize the emergency brake. Raise the rear of your car with a jack and place jack stands underneath.

Disconnect the fuel pump wire connector from the main wire harness located in the front of the engine compartment. Crawl under your Fiero and disconnect the fuel feed, fuel return, canister vent, the filler hose, and the breather hoses. Remove the heat shield covering the catalytic converter. Support the fuel tank with either a jack stand or another person and remove the support bracket and support straps. Lower the fuel tank with the front end of it tipped down.

The fuel pump is locked in to the fuel tank by a set of cams. Turn the inner ring clockwise using a brass punch and a hammer. After you have unlocked the fuel pump, carefully pull it out of the fuel tank.

Items you will need

  • Fuel pressure gauge

  • Jack

  • Jack stands

  • Phillips screwdriver

  • Flat head screwdriver

  • Socket wrenches

  • Brass punch

  • Hammer

 How to Replace a Fuel Pump in a Pontiac Grand Prix

Determine which fuel pump your Pontiac Grand Prix will need. This depends not only on the make and model, but also the engine size. Models made from 1962 to 1968 will have a 389 cubic inch (ci), 400 ci, 421 ci or 428 ci engine. Models built from 1969 to 1972 may be equipped with a 400 ci, 428 ci or 455 ci engine.

Look at later generations of the Pontiac Grand Prix. Models made from 1973 to 1977 may have a 231 ci, 350 ci, 400 ci or 455 ci engine. Models manufactured from 1978 to 1987 have 231 ci, 252 ci, 265 ci, 301 ci, 305 ci and 350 ci engines. Models made from 1988 to 1996 can be equipped with a 2.3 L, 2.8 L, 3.1 L or 3.4 L engine.

Examine the most recent versions of the Pontiac Grand Prix. Models made from 1997 to 2003 will have a 3.1 L or 3.8 L engine. The last generation was produced from 2004 to 2008 and had a 3.8 L, 3.8 L supercharged or a 5.3 L engine.

Prepare your vehicle for fuel pump servicing. Relieve the fuel system pressure and drain the fuel tank until it is one-quarter full. Disconnect the negative battery cable with a socket wrench. Remove the jack and spare tire so that you can remove the lining in the trunk. This will allow you to open the fuel sender access panel by removing the nuts with a socket wrench.

Remove the electrical connector from the fuel tank pressure sensor and fuel pump. Disconnect the quick connect fittings for the fuel pump. Remove the retaining ring for the fuel pump and take out the fuel pump assembly. Discard the old O-ring.

Install the new fuel pump using the items included in the kit, especially the new O-ring.

Complete the installation by reversing the removal procedure. Tighten the nuts on the access panel to 89 in. lbs. with a torque wrench.

Items you will need

  • Fuel pump kit

  • Socket wrench set

  • Torque wrench

About the Author

This article was written by the It Still Runs team, copy edited and fact checked through a multi-point auditing system, in efforts to ensure our readers only receive the best information. To submit your questions or ideas, or to simply learn more about It Still Runs, contact us.