How to Change the Fuel Pump on a 2002 Chevy Silverado

The fuel pump in a 2002 Chevrolet Silverado is responsible for taking the fuel from the gas tank and pushing it to the fuel-injection system of the engine. This pump is critical to the proper operation of the truck and if it fails or stops pushing fuel at the same rate as when new, the engine will run rough or may not run at all. To fix the problem, the fuel pump has to be removed from the vehicle and replaced with a new one.

Things You'll Need

• Jack
• Jack stands
• 2-foot long wood block
• 3/8-inch ratchet, extension and socket set
• Torx-head socket set
• Brass drift
• Brass hammer
• Replacement fuel pump assembly

Instructions

1. Lift up the driver's side of the vehicle using the jack and support it by jack stands. Open the gas door and disconnect the bolts securing the gas filler neck to the bedside, using the 3/8-inch ratchet and socket and a torx-head socket. Unbolt the ground strap securing the filler neck to the side of the frame with the ratchet.

2. Put the wood block onto the head of the jack. Lift up the jack until it contacts the gas tank. Unbolt the gas tank straps from the gas tank, using the 3/8-inch ratchet, extension and sockets, then slowly lower the jack until you can access the top of the gas tank.

3. Disconnect the plastic clips to the fuel lines by pushing the white clips inside of the fuel lines with your fingers, then pull the line off the fitting on the fuel pump. Unplug the harness on the fuel pump assembly. Lower the tank all the way, then pull it out from underneath the truck.

4. Remove the retaining ring around the fuel pump, using the brass drift and hammer. Lift out the old fuel pump and discard it. Set the replacement fuel pump into the gas tank, then secure it in place, using the stock retaining ring and brass drift and hammer. Slide the tank underneath the truck again, reconnect the fuel lines and wiring harness, then lift it up to the frame. Reconnect the gas tank straps to the frame with the 3/8-inch ratchet, extension and sockets, then connect the gas door and ground strap with the ratchet.

Tips & Warnings

• Never smoke or have an open flame nearby while you're working on the fuel system of a vehicle. If you do, you risk causing a fire and injuring yourself or damaging the vehicle.

References

• "Chilton General Motors Full-Size Trucks 1999-06 Repair Manual"; Jeff Kibler; 2007