How to Replace the Fuel Pump on a Chevy Truck

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The electric fuel pump on your Chevy truck model is located inside the fuel tank. In order to replace it, you need to lower the tank. It is a job you can do yourself, but having a helper makes it easier. Once you have the new replacement fuel pump, follow this guide to remove the old pump and install the new unit.

Things You'll Need

  • Wrench
  • Shop rag
  • Small screwdriver
  • Hand siphon pump
  • Fuel-approved container
  • Floor jack
  • 2 jack stands
  • 2 chocks
  • Ratchet, ratchet extension and socket
  • Drift punch
  • Hammer
  • New O-ring seal

Relieve the Fuel System Pressure

  • Unplug the fuel pump relay if you have a 1995 through 1997 2.2-liter engine model. See your particular car owner's manual for the location of the relay. If you have a different model, go to Step 4.

  • Start the engine and let it idle until it stalls. Then crank the engine to remove the remaining pressure and plug the fuel pump relay.

  • Disconnect the black battery cable using a wrench. Then go to the next section.

  • Locate the Schrader valve on the fuel rail inside the engine compartment. The valve is at the end of the rail and is similar to an air valve on a bicycle tire.

  • Wrap a shop rag around the valve and depress the valve using a small screwdriver. The rag will help you catch the squirt of fuel as you relieve the system pressure.

Remove the Fuel Pump

  • Drain the fuel tank, if necessary, through the filler neck using a hand siphon pump. Store the fuel in an approved container.

  • Raise the rear of your Chevy truck using a floor jack, support it on two jack stands and chock the front tires.

  • Remove the fuel tank shield using a ratchet, ratchet extension and socket.

  • Support the fuel tank with the floor jack and unscrew the tank straps using the ratchet, ratchet extension and socket.

  • Lower the tank just enough to reach the fuel lines, vapor hose and electrical connector on the tank and fuel pump/sending unit assembly.

  • Disconnect the fuel lines and vapor hose from their fittings by pressing the lock tabs and pulling the lines off. Then unplug the fuel pump electrical connector.

  • Lower the tank to the floor.

  • Unscrew the fuel pump/sending unit-locking ring using a drift punch and a hammer. Turn the ring counterclockwise until it frees from the assembly.

  • Lift the fuel pump/sending unit assembly from the tank and discard the O-ring seal located underneath the assembly flange.

Install the Fuel Pump

  • Install the new fuel pump on the fuel pump/sending unit assembly and mount the assembly in the fuel tank using a new O-ring seal.

  • Screw the fuel pump/sending unit-locking ring using the drift punch and hammer. Turn the ring clockwise until the ring hits the stops.

  • Lift the fuel tank with the floor jack just enough to connect the fuel lines, vapor hose and plug fuel pump electrical connector.

  • Set the fuel tank in place and tighten the fuel tank straps using the ratchet, ratchet extension and socket.

  • Install the fuel tank shield using the ratchet, ratchet extension and socket.

  • Lower the truck and refill the fuel tank.

  • Attach the black battery cable using the wrench.

  • Start the engine and check for leaks.

Tips & Warnings

  • When working in the fuel system of your Chevy truck, avoid smoking near the vehicle, and park away from appliances with open flames like driers and water heaters to avoid serious accidents.

References

  • Chevrolet S-10 and GMC Sonoma pick-ups; Max Haynes; 2008
  • Modern Automotive Technology; James E. Duffy; 2003
  • Photo Credit IFCAR/Wikipedia.org, crashycrashcrash/Flickr.com
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