How to Change the Fuel Pump in a 1999 Chevrolet Silverado

Once gas is in a tank, the fuel pump moves it into the engine.

For an experienced and confident do-it-yourself mechanic, replacing a fuel pump is a relatively easy job. The electric fuel pump on a Chevrolet Silverado is not serviced separately, so there are no complex rebuilds involved, only replacement of the entire module. It is a time-consuming process, requiring the removal of the gas tank, but with patience, you can save yourself hundreds of dollars in repair costs in a single afternoon.

Things You'll Need

• Screwdriver
• Pliers
• Replacement fuel pump module
• Shop rag

Instructions

1. Remove the Silverado's gas cap.

2. Open the fuse and relay box in the engine compartment.

3. Remove the fuel pump relay, using the underside of the fuse box cover to find the relay location for the truck.

4. Turn the ignition key to the "Start" position for several seconds. The engine will either start and quickly stall, or it won't start at all.

5. Turn the key to the "Off" position.

6. Disconnect the cable from the negative terminal of the battery. If your Silverado is equipped with a Theftlock audio system, turn off the lockout feature before disconnecting the battery.

7. Remove the fuel tank from the vehicle.

8. Disconnect the fuel lines and evaporation line from the fuel pump module.

9. Rotate the fuel pump module retaining ring counterclockwise with pliers while prying the locking tab out with a screwdriver.

10. Remove the fuel pump slowly to avoid damaging the fuel level sending unit float.

11. Transfer the fuel pressure sensor and fuel level sending unit to the new fuel pump module assembly.

12. Clean the fuel tank sealing surface with a shop rag.

13. Align the fuel line fittings with the fuel lines and install the fuel pump module.

14. Press the fuel pump module down until seated and replace the retaining ring.

15. Engage the locking tab of the retaining ring with the slot.

16. Reconnect the fuel lines and evaporation line.

17. Replace the fuel tank.

18. Reconnect the negative terminal of the battery.

19. Reconnect the fuel pump relay.

20. Replace the gas cap.

Tips & Warnings

• Do not attempt this repair around open flames or other potential causes of combustion.

References

• "Chilton General Motors Full-Size Trucks 1999-2005 Repair Manual;" Jeff Kibler; 2005