Here's a general outline of the process. This is NOT a substitute for a proper repair manual specific to your 1987 Pontiac Fiero GT. Consult a Haynes or Chilton manual for detailed instructions, diagrams, and torque specifications. Improperly following these steps could damage your car.
1. Safety First:
* Disconnect the battery's negative terminal. This is crucial to prevent accidental sparks.
* Ventilate the area: Work outside or in a well-ventilated garage.
* Obtain safety glasses and gloves.
* Have proper tools ready (see below).
2. Preparation:
* Gather tools: You'll need a socket set (various sizes), wrenches, screwdrivers (Phillips and flathead), jack stands, jack, fuel pump pliers (if applicable), a siphon pump to drain the fuel tank, safety glasses, gloves, rags, and possibly a torque wrench.
* Drain the fuel tank: Use a siphon pump to carefully remove as much fuel as possible. You can then use a shop vac to get rid of any remaining fuel. Dispose of the fuel properly.
3. Fuel Tank Removal:
* Locate the fuel tank: It's located under the car, usually toward the rear.
* Raise and secure the vehicle: Use jack stands to support the car safely. NEVER work under a car supported only by a jack.
* Disconnect fuel lines: Loosen the fuel lines carefully, using fuel line disconnect tools if necessary. Have rags ready to soak up any spilled fuel. Be absolutely sure to identify which line is the fuel feed and which is the return. Mark them clearly.
* Disconnect the electrical connectors: Disconnect the electrical connector to the fuel sending unit.
* Disconnect any other connections: This might include a vent line and possibly other sensors depending on your model.
* Lower the fuel tank straps: Carefully lower the fuel tank straps or bolts holding the tank in place. You may need to loosen them and then support the tank with jack stands before fully removing them. The tank is heavy, so proceed cautiously.
* Lower the fuel tank: Gently lower the fuel tank. It might be helpful to have a helper.
4. Fuel Sending Unit Replacement:
* Access the sending unit: The sending unit is usually located on the top of the fuel tank.
* Disconnect the float arm: Disconnect the float arm from the unit.
* Remove the retaining ring or bolts: Carefully remove the retaining ring or bolts holding the sending unit in place.
* Remove the old sending unit: Gently remove the old sending unit.
* Install the new sending unit: Install the new sending unit, ensuring it's properly seated.
* Reconnect the float arm: Carefully reconnect the float arm to the unit.
* Reinstall the retaining ring or bolts: Secure the sending unit with the retaining ring or bolts.
5. Fuel Tank Reinstallation:
* Reinstall the fuel tank: Carefully lift the fuel tank back into place and secure the straps.
* Reconnect fuel lines: Reconnect the fuel lines, ensuring they are securely fastened.
* Reconnect the electrical connectors: Reconnect the electrical connector to the fuel sending unit and other connectors.
* Lower the car: Carefully lower the car from the jack stands.
6. Final Steps:
* Reconnect the battery: Reconnect the battery's negative terminal.
* Check for leaks: Carefully inspect all connections for leaks.
* Prime the fuel system: Some vehicles require priming the fuel system after a fuel tank removal. Check your repair manual for instructions.
* Test the fuel gauge: Start the car and check if the fuel gauge is working correctly.
Remember, this is a simplified overview. Always consult a repair manual specific to your 1987 Pontiac Fiero GT for detailed instructions and safety precautions. If you're not comfortable performing this repair yourself, it's best to take your car to a qualified mechanic. Improperly working on your fuel system can be dangerous.
