Here's a general outline of the process. Specific steps and tools may vary slightly depending on your engine (2.2L or 3.4L). Always consult a repair manual specific to your vehicle's year, make, model, and engine for detailed instructions and torque specifications. A Haynes or Chilton manual is a good investment for this type of work.
Safety First:
* Disconnect the negative battery terminal before starting any work.
* Work in a well-ventilated area. Fuel fumes are flammable and dangerous.
* Wear safety glasses and gloves.
* Have a fire extinguisher nearby.
Steps (General Outline):
1. Vehicle Preparation: Raise the vehicle securely on jack stands. Never work under a vehicle supported only by a jack.
2. Access the Fuel Pump: This usually involves dropping the fuel tank. The process varies depending on the Grand Am's configuration. You may need to:
* Remove the rear seat (often requires removing some plastic trim).
* Disconnect the fuel lines (requires specialized fuel line disconnect tools to avoid spills).
* Disconnect the electrical connector to the fuel pump.
* Remove the fuel tank straps and lower the tank (this might require loosening the exhaust system slightly).
3. Remove the Fuel Pump Assembly: The fuel pump is typically housed within a sending unit at the top of the fuel tank. This assembly will need to be removed. It's often held in place by a retaining ring or bolts.
4. Replace the Fuel Pump: Once the assembly is removed, you can access the fuel pump. Carefully compare the new pump to the old one to ensure proper installation. Take note of the orientation of any components.
5. Reassembly: Install the new fuel pump assembly in reverse order of removal, ensuring everything is seated correctly. Double-check all connections.
6. Reconnect the Fuel Lines and Electrical Connector: Use the appropriate fuel line disconnect tools to reconnect the lines securely and prevent leaks.
7. Raise the Fuel Tank: Carefully raise the fuel tank back into its position and secure it with the straps.
8. Reconnect the Battery: Reconnect the negative battery terminal.
9. Prime the Fuel System: You may need to prime the fuel system (your repair manual will detail how to do this). This ensures the fuel lines are full before attempting to start the vehicle. This might involve turning the ignition key to the "on" position several times without actually cranking the engine.
10. Test the Vehicle: Start the vehicle and check for any leaks. Listen for any unusual noises from the fuel pump.
Important Considerations:
* Fuel Pressure: Some fuel pumps require a pressure test after installation to ensure proper operation.
* Fuel Tank Removal: This is the most challenging part. You might need special tools to reach certain bolts or connectors.
* Fuel Line Disconnection: Be extremely careful when disconnecting fuel lines to avoid spillage and injury. Use the appropriate tools and cloths to absorb any fuel that might spill.
Again, this is a general overview. Refer to a repair manual specific to your 2004 Pontiac Grand Am for detailed instructions, diagrams, and torque specifications. Failing to follow proper procedures could damage your vehicle or cause injury. If you're unsure about any step, consult a professional mechanic.
