How to replace the fuel pump on a chevy pickup

Written by gregory crews
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How to replace the fuel pump on a chevy pickup
The fuel pump pushes the gasoline from the back of the truck to the engine. (pumping gas image by Mat Hayward from Fotolia.com)

The fuel pump in a Chevrolet truck is located in the fuel tank. Replacement of the fuel pump consists of dropping the fuel tank to the ground and pulling it out of the tank. Once the pump is replaced, you will notice a great improvement in your acceleration and fuel economy. Depending on the truck, you can choose to place it on jack stands for more room to work. This job can be done on some trucks without raising it.

Skill level:
Moderate

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Things you need

  • Siphon kit
  • Drain pan
  • Jack
  • Chock
  • Jack stands
  • Socket set
  • Socket wrench
  • Flathead screwdriver
  • Punch
  • Hammer
  • Fuel pump kit

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Instructions

    Removing the Fuel Pump

  1. 1

    Park the truck on a flat, level surface. Set the parking brake.

  2. 2

    Open the bonnet to access the engine compartment. Locate the fuse panel behind the battery. Open the fuse panel and pull out the fuse entitled "Fuel Pump." Start the truck and allow it to run until it stalls. This will relieve the pressure in the fuel line.

  3. 3

    Siphon the gasoline out of the fuel tank with a siphon kit. You can purchase this kit at the local automotive parts store. The drained fuel tank will be easier to manage.

  4. 4

    Raise the back of the truck with a car jack. Place two jack stands under the frame rail. Lower the jack down on the jack stands. This will provide more room to work.

  5. 5

    Place a jack underneath the fuel tank. The jack will support the tank so you can remove the straps. Unbolt the two straps with a socket wrench. Slowly lower the tank by lowering the jack. The fuel lines and electrical wires on the top of the tank will be visible.

  6. 6

    Disconnect the wires by pulling the locking tab on the wiring connector. Separate the two connectors. Pull the fuel lines away from the piping.

  7. 7

    Detach the filler hose at the back of the fuel tank by unscrewing the hose clamp with a flathead screwdriver. Pull the hose off with your hands.

  8. 8

    Lower the tank to the ground by lowering the jack. Slide the tank out from underneath the truck.

  9. 9

    Tap the retainer ring at the top of the tank with a punch and a hammer. A flathead screwdriver can act as a punch. Push the ring counterclockwise to remove it from the fuel tank. Pull the ring off and this will give access to the fuel pump assembly. Pull the harness out of the fuel tank by lifting at an angle from the pump.

  10. 10

    Replace the O-ring on the threads of the tank. The new O-ring is uncluded with the fuel pump.

  11. 11

    Separate the fuel pump from the assembly. Disconnect the wiring harness at the top of the pump.

    Installing the Fuel Pump

  1. 1

    Tighten the new strainer to the bottom of the pump with a socket wrench. The pump will come with the new strainer.

  2. 2

    Position the pump on the assembly. Insert the wiring connector at the top of the pump.

  3. 3

    Place the assembly in the fuel tank. Insert it at an angle to prevent bending the fuel sending unit.

  4. 4

    Place the fuel tank on the jack. Slide both under the truck. Raise the jack high enough to attach the wires and lines to the tank. Push the wiring connectors together until they lock. Attach the fuel lines by pushing them onto the piping.

  5. 5

    Push the filler hose onto the back of the tank. Slide the hose clamp over the hose and the nozzle. Tighten it with a flathead screwdriver.

  6. 6

    Push the tank up to the bottom of the truck. Position the straps to the tank. First, hand-tighten the bolts. Then tighten all the bolts with the socket wrench.

  7. 7

    Raise the truck with the jack. Remove the jack stands and lower the truck to the ground.

  8. 8

    Pour the gasoline back into the gas tank. Insert the fuse to power the fuel pump.

  9. 9

    Insert the key in the ignition and turn it to the "Start" position. Hold in the "Start" position for five seconds. This will prime the fuel lines. Turn the key to start the truck. The truck may take a minute to start. There may be air stuck in the fuel line. The air will be pushed out by the fuel. Allow the truck to start.

  10. 10

    Let the truck idle for five minutes. Observe the fuel tank for any leaks.

Tips and warnings

  • The fuel pump, O-ring and strainer will come as a fuel pump kit.
  • Use caution when working under the truck. Ensure that the front wheel is chocked.
  • Use caution when working around gasoline. Gasoline is highly toxic and flammable.

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