How to Replace a Fuel Pump on a Chevrolet Truck

With both full and mid-size Chevrolet trucks, the fuel pump is contained within the fuel tank itself. The pump cannot be separated from its module, so replacing the pump means replacing the entire module. In order to do this, you need to disconnect the fuel tank from the truck This procedure varies only slightly between mid-size trucks like the Colorado and full-size ones like the Silverado.

Difficulty:

Moderately Challenging

Instructions

Things You'll Need

• Jack stands
• Wrench
• Screwdriver
• Fuel siphoning kit
• Clean gas can
• Transmission jack
• Vise-grip pliers
• Replacement fuel pump module

1. De-pressurize the truck's fuel system. Open the fuel tank by removing the cap and disconnect the fuel pump relay from the fuse box in the engine compartment. Start the engine and let it stall, then crank it for another five to ten seconds.

2. Disconnect the truck's negative battery cable. Siphon all fuel out of the tank into a clean gas can using a siphoning kit from an auto parts store. On a full-size truck like the Silverado, disconnect the screws holding the fuel filler tube's flange to the body.

3. Raise and support the truck on jack stands. On a mid-size truck, remove the left rear fenderwell liner. On full-size trucks, remove the shield on the tank (if equipped), the fuel filler pipe's ground strap and the EVAP canister.

4. Disconnect the fuel supply and return lines from the tank and the EVAP vapor lines. Remove the filler hose from the tank if it disconnects (usually on mid-size trucks).

5. Support the fuel tank with a transmission jack underneath it. Remove the straps holding the tank in place by removing its bolts. Disconnect the electrical connectors and lower the jack to remove the tank and fuel pump module. Disconnect the fuel and EVAP lines from module.

6. Remove the fuel pump module from the tank. Release the locking tab with a pointed tool while rotating the locking ring counter-clockwise with vise-grip pliers, then lift the module out.

7. Install the new fuel pump module within the tank, making sure the fuel lines are aligned with their fittings. Press the module down into the tank until it is seated. Install and, making sure it is fully seated and the locking tab is engaged within the slot.

8. Re-install everything on the truck in reverse order of installation. Refill the tank with at least five gallons of gas, starting with the siphoned fuel. Reconnect the fuel pump relay and the negative battery cable.

9. Re-pressurize the fuel system by turning the ignition switch on for a couple of seconds and then back off for about ten. Repeat this five to ten times.