How to Replace a Chevy Fuel Pump

Most Chevy vehicles have the fuel pump stored within the fuel tank, contained within a module. Replacing the fuel pump means replacing the entire module, and you must remove the tank to access it. The exact method of replacing the pump can vary, depending on the make and model of your Chevy.

Things You'll Need

• Jack
• Jack stands
• Lug wrench
• Siphoning kit
• Wrenches (socket and Torx)
• Transmission jack
• Lacquer thinner/acetone
• Fuel pump module

Instructions

Removing the Fuel Tank

1. Relieve the pressure in the fuel system: remove the fuel pump relay, which should be stored within the fuse box inside the engine compartment, then crank the engine and look for it to stall or not start.

2. Disconnect the negative cable from the car battery. The cable may have a snap-on connector, or you may need to loosen a clamp nut with a wrench.

3. Raise the rear end of the vehicle and support it on jack stands; make sure the parking brake is applied and block the wheels. Remove the wheel closest to the fuel tank -- the one closest to the fuel cap.

4. Siphon as much fuel out of the tank as you can and pour the fuel into an approved container. Use a siphoning kit -- never siphon out gasoline by mouth.

5. Remove any components connected to the tank in any way. On trucks like the Silverado, for example, this includes the flange connecting the filler tube to the body (the screws are on the outside near the cap and should require a Torx wrench) and the EVAP canister by disconnecting its hoses and mounting bracket bolt. On other models, you may need to disconnect the filler neck hose by loosening its clamps.

6. Raise a transmission jack directly under the tank to support it. Unbolt the straps to the tank with a wrench so you can remove the straps.

7. Lower the jack and the tank with it until you can reach the electrical connector to the fuel pump module and disconnect the connector. Lower the jack the rest of the way and remove the tank.

Replacing the Pump

1. Disconnect all lines connected to the fuel pump module; this usually includes the fuel and EVAP lines, which have quick-connect fittings that you press on the tabs to remove.

2. Remove the locking ring on the module by pressing the locking tab with a needle-nose instrument and rotating the ring with a set of locking pliers; you normally need to rotate it counterclockwise.

3. Pull the fuel pump module out of the tank at an angle so you don't damage the float on the fuel sending unit.

4. Clean the surface of the tank around the sealing surface for the module, using acetone or lacquer thinner.

5. Install the new pump module into the tank; align it so the fittings to the fuel lines line up with the lines themselves. Press the pump down until it is seated, install the retaining ring so the locking tab engages within the slot and connect the fuel and EVAP lines.

6. Connect the fuel tank back onto the vehicle in the reverse order of removal, then replace the wheel if needed and lower the vehicle. Reconnect the fuel pump relay and the battery cable.

Tips & Warnings

• To help re-pressurize the fuel system, repeatedly turn the ignition switch on and off, leaving it on for two seconds and off for five.

References

• "Chilton General Motors Full Size Trucks Automotive Guide;" Jeff Kibler; 2006
• "Chilton General Motors Colorado/Canyon Repair Manual;" Jay Storer; Haynes North America; 2006