Chevy Suburban Fuel Pump Installation Instructions


The Chevrolet Suburban is the largest sport utility truck in the Chevrolet lineup. This truck is known for its power and cargo space. The Suburban is equipped with a fuel pump that is in the fuel tank. Replacing a faulty pump will require pulling the fuel tank down. The pump comes in a kit that includes the strainer, o-ring and pump. Pulling the tank down is the hardest part of the task.

Things You'll Need

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

Removing the Fuel Pump

  • Make sure the truck is parked on a flat surface. Push the parking brake down with your foot. Chock the front wheels at the front. This will prevent the truck from rolling forward when it is lifted.

  • Open the hood to access the engine compartment. Open the fuse panel behind the battery. Pull the fuse labeled "fuel pump." Start the truck and let it idle until the truck stalls. This will take the pressure off the the fuel line.

  • Remove the fuel from the gas tank with a siphon kit. This kit can be purchased at an automotive-parts store. Draining the fuel in a drain pan will make the gas tank lighter and easier to manage.

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

  • Move the jack underneath the fuel tank. This will support the tank so you can unbolt the straps with a socket wrench. Unbolt the straps and place them to the side. Lower the tank enough to access the fuel and electrical lines at the top of the fuel tank.

  • Separate the wiring harness by pulling the locking tab on the wiring connector. Separate the two connectors by pulling them apart.

  • Disconnect the filler pipe at the back of the fuel tank by unscrewing the hose clamp with a flat head screwdriver.

  • Lower the tank to the ground. Lift the tank off the jack.

  • Push the retainer ring at the top of the tank with a punch and a hammer counter-clockwise . A flat head screwdriver can also act as a punch. Pull the ring off to access to the fuel pump assembly. Pull the assembly out at an angle to free from the tank.

  • Remove the old o-ring and replace with a new one. The fuel pump kit includes a new o-ring, strainer and pump.

  • Pull the fuel pump out of the assembly. Unplug the wiring harness at the top of the pump.

Installing the Fuel Pump

  • Install the new strainer to the pump with a socket wrench. The strainer bolts at the bottom.

  • Insert the pump to the assembly. Connect the wiring lead at the top of the pump.

  • Place the assembly in to the fuel tank at an angle. This will prevent the fuel sending unit from getting bent. When the sending unit is bent, this will effect the fuel gauge.

  • Position the fuel tank on to the jack. Slide under the truck. Raise the tank high enough to attach the wires and fuel lines to the top of the tank. Connect the wiring harness together. Push the fuel lines on to the piping at the top of the tank.

  • Tighten the filler hose to the back of the tank. Place the hose clamp over the hose and nozzle. Tighten the clamp with a flat head screwdriver.

  • Push the tank the remaining distance to the bottom of the truck. Connect the straps and hand tighten all the bolts. Tighten the bolts with a socket wrench.

  • Lift the truck up with the jack. Slide the jack stands out from under the truck. Lower the truck to the ground.

  • Pour the gasoline in to the fuel tank. Insert the fuse to the fuse panel.

  • Turn the ignition as if you were starting the truck. Stop at the "start" position. Leave the key in this position for five seconds. This will cycle the fuel pump and prime the fuel line. Turn the key the rest of the way to start the Suburban.

  • Allow the truck to idle for five minutes. Observe the fuel tank for any leaks.

Tips & Warnings

  • Allowing the truck to sit overnight will also relieve the pressure in the fuel line. This will make for a less messy removal of the fuel line.
  • Replacing the fuel filter will provide a complete overhaul of the fuel system and greatly enhance your fuel mileage and life of your fuel pump.
  • Use caution when working around gasoline. Gasoline is highly toxic and flammable.
  • Use caution when working under a raised vehicle.

Related Searches


  • Automedia: Fuel Pump Replacement
  • Aa1car: Tutorial on Fuel Pumps
  • "Chevrolet and GMC Pick-ups Haynes Repair Manual for 1988 thru 1998 Full-size Light-duty Gasoline Engine Models. Includes 1999 and 2000 C/K Classic models, 1992 thru 1999 Suburban, 1992 thru 1994 Full-size Blazer and Jimmy, 1995 thru 1999 Tahoe, and 1992 thru 1999 Yukon "; John Haynes; 1999
  • Photo Credit pumping gas image by Mat Hayward from
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