* Disconnect the negative battery terminal. This prevents accidental sparks.
* Work in a well-ventilated area. Fuel vapors are dangerous.
* Have a fire extinguisher readily available.
* Wear safety glasses and gloves.
* Obtain a repair manual specific to your 2001 Pontiac Montana. This will provide detailed diagrams and instructions. A Haynes or Chilton manual are good options.
The general steps are as follows, but always refer to your repair manual for precise instructions and torque specifications:
1. Drain the fuel tank. This is crucial to minimize the amount of fuel you'll be working around. You'll need a siphon pump or to carefully lower the fuel level by driving the vehicle until nearly empty.
2. Lower the fuel tank. This is often the most challenging part. Access to the fuel tank may require removing other components, such as the spare tire, exhaust components, or even part of the rear bumper. You'll need to disconnect fuel lines, electrical connectors, and possibly the tank straps. Support the tank with jack stands to prevent it from falling. Be extremely careful not to damage the fuel lines.
3. Remove the fuel pump assembly. This typically involves removing a retaining ring or bolts securing the assembly to the top of the tank. Consult your repair manual for the specific procedure.
4. Disconnect the electrical connector and fuel lines. Note the orientation of the lines and connector so you can reassemble correctly. You might need a fuel line disconnect tool to avoid damaging the lines.
5. Replace the fuel pump and fuel filter (if necessary). Carefully install the new pump, ensuring it's seated correctly. Replace any worn-out gaskets or O-rings.
6. Reassemble everything. Carefully reconnect the fuel lines and electrical connector. Double-check everything before raising the fuel tank.
7. Raise the fuel tank and secure it. Ensure all connections are secure.
8. Reconnect the negative battery terminal.
9. Prime the fuel system. This may involve turning the ignition key on and off several times (without cranking the engine) or using a fuel pump priming tool. Refer to your repair manual.
10. Check for leaks. After reassembly, inspect all connections for leaks.
Important Considerations:
* Fuel pump pressure: You may need a fuel pressure gauge to check the pressure after installation.
* Fuel pump relay: A faulty fuel pump relay can mimic the symptoms of a bad fuel pump. It's cheaper to replace a relay first.
* Professional help: If you are uncomfortable performing this repair, it's best to have a qualified mechanic do it. Working with fuel is dangerous, and a mistake can lead to serious injury or property damage.
This is a general overview. The specific procedures will vary depending on your vehicle's configuration. Always refer to your vehicle's repair manual for detailed instructions. Taking shortcuts can lead to serious consequences.
