Here's a general overview. Specific steps and tools may vary slightly depending on your exact engine (2.0L or 2.5L). Consult a repair manual specific to your 1992 Pontiac Sunbird for detailed instructions and diagrams. A Haynes or Chilton manual is a good investment.
Safety First!
* Disconnect the negative battery terminal before starting any work.
* Work in a well-ventilated area. Fuel fumes are highly flammable and dangerous.
* Wear safety glasses and gloves.
* Have a fire extinguisher nearby.
* Dispose of fuel properly. Do not pour gasoline down a drain or onto the ground.
Tools You'll Likely Need:
* Socket wrench set (metric)
* Ratchet and extensions
* Screwdrivers (Phillips and flathead)
* Fuel line disconnect tool (or pliers, but a tool is recommended)
* New fuel pump and filter (get the correct part number for your engine)
* Jack and jack stands
* Drain pan
* Shop rags
* Torque wrench (optional, but recommended)
* Fuel pump installation tool (often needed to install the pump into the tank)
General Steps:
1. Prepare the vehicle: Raise the rear of the car and securely support it on jack stands. Locate the fuel tank access panel (usually under the rear seat or in the trunk).
2. Disconnect the fuel system:
* Release fuel pressure: Consult your repair manual for the specific procedure. This often involves disconnecting a wire to the fuel pump relay or using a special pressure release tool. This is crucial to prevent fuel spraying.
* Disconnect the fuel lines: Use the fuel line disconnect tool to carefully separate the fuel lines from the fuel pump. Have rags ready to absorb any spilled fuel.
* Disconnect the electrical connector: Disconnect the electrical connector from the fuel pump.
3. Access the fuel pump: This usually involves removing the fuel tank access panel, dropping the fuel tank (this might require disconnecting the fuel tank straps and the fuel tank filler neck), or working through an access hole in the floor of the trunk. Refer to your repair manual for the proper method for your specific model. You might need to remove the fuel pump assembly from the tank.
4. Remove the old fuel pump: Once you access the fuel pump, carefully remove it from the tank. Note the orientation and any specific installation features (o-rings, gaskets, etc.).
5. Install the new fuel pump: Carefully install the new fuel pump, ensuring that all gaskets and o-rings are properly seated. Use the fuel pump installation tool if required.
6. Reassemble everything: Reinstall the fuel pump assembly, fuel tank, access panel, and reconnect the fuel lines and electrical connector.
7. Reconnect the battery: Reconnect the negative battery terminal.
8. Check for leaks: Inspect all fuel line connections for leaks.
9. Start the engine: Start the engine and check for proper fuel pressure. Listen for the whirring sound of the fuel pump.
Important Considerations:
* Fuel tank removal: Dropping the fuel tank can be tricky and may require additional tools and steps not listed above. Your repair manual will provide specific details.
* Fuel pump installation tool: This tool is highly recommended to avoid damaging the new fuel pump during installation.
* O-rings and gaskets: Replace all O-rings and gaskets during the installation. These are critical for preventing fuel leaks.
This is a simplified overview. Always consult a repair manual specific to your 1992 Pontiac Sunbird before attempting this repair. Failure to follow proper procedures can lead to injury, damage to your vehicle, or fire. If you are not comfortable performing this repair yourself, seek professional help from a qualified mechanic.
