Here's a general outline. Specific steps and locations might vary slightly depending on the engine (2.0L or 2.5L) and body style. Always consult a repair manual specific to your 1990 Pontiac Sunbird for detailed instructions and diagrams. A Haynes or Chilton manual is a good investment.
Tools You'll Likely Need:
* Socket set (metric): Various sizes, including deep sockets.
* Wrench set (metric): Various sizes.
* Screwdrivers (Phillips and flathead):
* Fuel pump pliers or a fuel line disconnect tool: To safely disconnect fuel lines.
* New fuel pump and filter (if necessary): Make sure you get the correct part number for your specific vehicle.
* Jack and jack stands: To safely lift and support the vehicle.
* Fuel line clamps: If your fuel lines use clamps that need replacing.
* Safety glasses and gloves: Essential for protection.
* Shop rags or absorbent towels: To clean up any spilled fuel.
* Torque wrench: To tighten bolts to the manufacturer's specifications.
* Fuel pressure gauge (optional but recommended): To check fuel pressure after installation.
General Steps:
1. Safety First: Disconnect the negative battery terminal.
2. Access the Fuel Pump: The fuel pump is usually located inside the fuel tank, requiring tank removal or dropping the tank slightly. This is often the most challenging part. Consult your repair manual to determine the best access method for your specific Sunbird. You may need to remove the rear seat, access panels, or even lower the fuel tank (which may involve disconnecting fuel lines and the tank straps).
3. Disconnect Fuel Lines: Carefully disconnect the fuel lines using the appropriate tools. Have rags ready to absorb any spilled fuel. Be extremely careful not to damage the lines. Some systems use quick-disconnect fittings, while others may require clamps.
4. Disconnect Electrical Connector: Disconnect the electrical connector to the fuel pump.
5. Remove the Fuel Pump Assembly: Once the fuel lines and electrical connector are disconnected, you'll need to remove the fuel pump assembly from the tank. This often involves removing a retaining ring or cover. The pump is usually held in place by a retaining ring or clip.
6. Install the New Fuel Pump: Carefully install the new fuel pump assembly, ensuring it's seated correctly. Re-attach the retainer.
7. Reconnect Everything: Reconnect the fuel lines, electrical connector, and any other components removed during the process. Ensure the fuel lines are securely connected to prevent leaks.
8. Lower the Fuel Tank (if applicable): If you lowered the tank, carefully raise it back into place and secure it.
9. Reconnect the Battery: Connect the battery negative terminal.
10. Check for Leaks: Carefully inspect all connections for leaks. Start the vehicle and let it run for a few minutes to check for leaks and proper fuel pressure. Use the optional fuel pressure gauge to verify pressure is within specifications.
Important Considerations:
* Fuel Pressure: Some fuel systems require bleeding the air from the lines after the pump replacement.
* Fuel Tank Removal: This can be a labor-intensive process and may require special tools.
* Safety: Working with fuel is dangerous. Take all necessary precautions.
* Repair Manual: This is not a substitute for a proper repair manual. Always refer to your vehicle's repair manual for precise instructions and safety information.
This is a simplified overview. The actual procedure can be quite involved and varies depending on your vehicle's specific configuration. Consult a professional mechanic if you are not comfortable performing this repair yourself. Improper installation can lead to serious safety hazards.
