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Old 01-02-2013, 05:02 PM   #1
jam01
 
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2002 pontiac sunfire fuel pump

has anyone changed a fuel pump on one of these cars, its my daughters and i got volunteered into fixing it. it has a 2.2 automatic and its yellow, anyway is this a real pain or a fairly easy fix. any suggestions? thank you for any help
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Old 01-03-2013, 07:34 AM   #2
sweetbmxrider
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Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
Drain the fuel tank. Refer to Fuel Tank Draining Procedure.
Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
Disconnect the quick-connect fitting at the fuel filter.
Disconnect the fuel return pipe quick connect fitting.
Remove the rubber exhaust hangers. Allow the exhaust system to rest on the rear axle.
Remove the exhaust heat shield.
Loosen the fuel filler hose clamp at the fuel tank.
Disconnect the fuel filler hose from the fuel tank.
Disconnect the evaporative emission (EVAP) vapor pipe from the EVAP canister.
Disconnect the electrical harness from the multi-way rear body connector and fuel strap.
With the aid of an assistant, support the fuel tank (1).
Disconnect the fuel tank retaining straps.
Lower the fuel tank.
Remove the fuel sender assembly from the tank.

I'd pull the backseat/trunk carpet and make sure there isn't an access hole first.
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Old 01-03-2013, 07:49 AM   #3
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There is no access from the trunk floor pan from what I remember. I also don't recall them being too difficult but I have the luxury of working on a lift. Only thing I can think of that may give you problems is the fuel line clips, GM went through a few different clips in the early 00's and one design in-particular always gave me issues. I know they used the PITA clips on Grand Ams but Im not sure if they used the same ones on Sunfires.
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Old 01-03-2013, 12:08 PM   #4
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thanks guys, unfortunately ill be doing this in a driveway and it wont be mine. ill have to bring my tools with me which sucks because you know you always forget something.
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Old 01-14-2013, 03:02 PM   #5
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i finished the car last weekend, i got it started by banging on the tank so i could do it in my driveway. while it was not a total pain in the butt, it also wasnt easy. first i had loaned my line tools to someone and never got them back. second i bought a set from harbor freight, i thought i had gotten a good set you know the $19.99 for the aluminum. well there made just a little to big to fit, ah live and learn. i ended up using a screwdriver. oh and my daughter called me late in the day, so it took me into the night and of course it got cold. just wanted to give a warning on those cheap tools and another thank you for the replys because it did help.
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Old 01-14-2013, 03:05 PM   #6
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Glad you got it started. Yeah, the cheap tools are sometimes cast extra big so they can be made of cheaper material.

I had to buy a 3/4" drive set from HF two weeks ago, and while it's not too bad the ratchets were totally dry and very loud. Had to open them up and grease 'em.
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Old 01-14-2013, 07:55 PM   #7
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I have found most of the time the metal line disconnect tools don't work. I like the plastic ones. I have a case that has a double sided metal one, an array of plastic ones with some handle to them, and the typical white ones. Usually one gets the job done hahaha
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