Replacing Fuel Pump In 2002 Firebird: Step-By-Step Guide

Replacing the fuel pump on a 2002 Firebird is a complex process. The fuel pump is directly connected to the fuel tank, so to replace it, you must disconnect and remove the tank from the car. Before starting, relieve the pressure in the fuel system and drain the gas from the tank. You will also need to disconnect the negative battery cable and remove the fuel pump fuse. Once the tank is removed, you can disconnect the fuel sender from the tank and remove the old fuel pump. Install the new fuel pump onto the fuel sender, and then reattach the sender to the tank. Refill the tank, reconnect the battery cable and fuel system fuse, and you're almost done. Turn the ignition on and off a few times to restore pressure in the system and check for leaks.

Prepare the fuel pump for replacement

To prepare the fuel pump for replacement, you must first relieve the pressure in the fuel system. Open the gas cap, then 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.

Next, disconnect the negative battery cable. It is important to ensure that the negative battery terminal is disconnected before proceeding with the fuel pump replacement.

Now, you will need to raise the car using jack stands to access the fuel tank. Make sure the car is securely supported by the jack stands and place approved containers underneath the tank to collect the drained fuel. Remove the tank's drain plug or the line running to the fuel filter. Be cautious and ensure you know the amount of fuel in the tank before proceeding.

Before removing the fuel pump, it is important to clean the fuel system's exterior, especially the area around the fuel-sender assembly. This will help prevent any contaminants from entering the fuel system during the disassembly process.

Now you are ready to disconnect and remove the fuel tank and sender assembly from the fuel pump. Carefully disconnect the fuel sender from the tank by removing its retaining ring. At this point, you have successfully prepared the fuel pump for replacement and can proceed to install the new fuel pump.

Remove the fuel tank

To remove the fuel tank from a 2002 Firebird, first 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.

Now, raise the car on jack stands. 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.

Next, 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.

Finally, remove the tank. This may be the most challenging part of the process. You may need to cut the exhaust pipe to get it out of the way. You will also need to disconnect all the lines. The gas cap portion of the tank, or the arm part, may get caught on the bodywork, so be careful and take your time. You may need to lower the rear end of the car to get the tank out.

Disconnect the fuel tank and sender assembly

To disconnect the fuel tank and sender assembly, you must first relieve the pressure in the fuel system. Open the gas cap, then go to the fuse box within the engine and remove the fuse for the fuel system. Next, start the engine and let it run until it stops. Now, disconnect the negative battery cable.

At this point, you can raise the car using jack stands and drain the fuel from the tank. Remove the tank's drain plug or the line running to the fuel filter. It is important to know how much fuel is in the tank and to have an approved container to pour it into.

Before disconnecting the fuel tank and sender assembly, clean the fuel system's exterior, especially around the fuel-sender assembly. This will prevent anything from contaminating the system when you take it apart.

Now, you are ready to disconnect and remove the fuel tank and sender assembly from the fuel pump. To do this, disconnect the fuel sender from the tank by removing its retaining ring, and then remove the pump from the sender.

Install the new fuel pump

Now that you have removed the old fuel pump assembly, it's time to install the new one. This process will involve carefully reconnecting various components and ensuring that everything is securely attached before refilling the fuel tank and restoring pressure to the system. Here is a step-by-step guide to installing the new fuel pump in your 2002 Firebird:

First, install the new fuel pump assembly. Make sure to follow the reverse process of how you removed the old fuel pump. Place the new fuel pump assembly into the trap door opening. Secure the fuel pump retaining ring by spinning it to lock it into place.

Connect the Fuel Lines and Electrical Connectors

Now, reconnect the three fuel lines by pushing them onto the plastic hose connectors and clipping them into place. Be careful not to spill any fuel. Then, connect the two electrical connectors on top of the fuel pump assembly by clipping them into place.

Clean the Trap Door Area

Before sealing the trap door, clean the area carefully to minimise the risk of dirt or debris falling into the fuel tank. Use rags and a cleaning solution to wipe down the trap door and its surrounding area.

Seal the Trap Door

To seal the trap door, get a piece of sheet metal and cut it to the same shape but slightly larger than the trap door. Lay this piece of sheet metal over the trap door, using a bead of RTV to create a secure seal. This will ensure that your cabin is sealed from the fuel tank.

Reconnect the Fuel Tank

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

Restore Pressure and Check for Leaks

Turn the ignition switch on (without starting the Firebird) for two seconds, switch it back off for 10 seconds, and then switch it back on. Repeat this process two to three times to restore pressure in the system. Finally, check for any leaks around the fuel pump area to ensure that your new fuel pump is installed correctly and there are no fuel spills.

Congratulations! You have successfully replaced the fuel pump in your 2002 Firebird. By following these steps, you have ensured that your car's fuel system is functioning optimally, and you can now enjoy improved engine performance and fuel efficiency.

Reconnect the fuel tank

To reconnect the fuel tank, first, 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.

Next, 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 then switch it back on. Repeat this two to three times to restore pressure in the system and check for leaks.

If you replaced the pump near a gas station when the car is low on fuel, you won't have to refill the tank with much fuel.

Finally, check for leaks and ensure that the fuel tank is securely connected.

Frequently asked questions