How to Change a Fuel Pump on a 2002 Sunfire
- 1). Raise the back of the car using the floor jack and support it on the jack stands. Disconnect the electrical harness plug to the fuel pump, which is located directly behind the fuel tank. Start the engine to relieve the fuel pressure in the lines. Turn the key off. Remove the top and bottom hose clamps on the filler hose. Remove the hose using a screwdriver.
- 2). Remove the lower clamp on the vent hose next to the tank. Pull this hose off. Disconnect the three plastic fuel lines behind the fuel tank by squeezing the connectors and pulling them apart. Place the floor jack under the fuel tank for support as the tank is lowered. Siphon some fuel out of the tank if the tank is over half full. Use the filler hose hole to siphon the fuel out.
- 3). Remove the two fuel tank strap support bolts using a socket. Lower the straps and rotate them down and out of the way. Lower the fuel tank to the ground and pull it out from under the car.
- 4). Remove the retainer, which seals the fuel pump in the tank. If it is a snap ring, use the screwdriver to pry the snap ring in and up to remove. If it is a cam lock ring, place the screwdriver tip on one of the vertical tabs and use the hammer to tap the tab counterclockwise to loosen it.
- 5). Lift the fuel pump out of the tank, keeping in mind that the module is full of fuel, so tip it as it comes out and pour the fuel back into the tank. Also be careful not to bend or damage the fuel sending unit arm as the pump is removed.
- 6). Pull the old O-ring out of the hole in the top of the fuel tank used for the fuel pump. Install a new O-ring so there is a good leak-free seal when the pump is installed. Install the fuel pump so that the fuel lines on top are facing in the correct direction. Push the pump, which is spring loaded, down and turn it as necessary to engage the single, small locating tab on the fuel pump with the cut-out on the fuel tank. Install the snap ring or cam lock ring. The cam lock ring should be tapped in a clockwise direction until the tabs on the ring are engaged with the tabs on the fuel tank.
- 7). Place the fuel tank on the floor jack and raise it back into position. Place the support straps under the fuel tank and insert the bolts and tighten. Remove the floor jack and reconnect the three fuel lines by pushing both ends together.
- 8). Install the filler hose and tighten the clamps with the screwdriver. Install the vent hose and tighten the clamp. Reconnect the electrical plug to the fuel pump electrical harness. Lower the car.