Replacing a Fuel Pump in a Chevy Pickup
The fuel pump, whether manual or electric, performs the task of delivering fuel to the intake system of a vehicle. It does this by using a pump vane or diaphragm to produce the pressure required to send it through the lines. The older Chevy trucks came equipped with a mechanical pump, located on the engine block. It uses a diaphragm to send fuel to the carburetor. The newer Chevy trucks have electrical pumps mounted in the gas tank or on top of the gas tank. Replacing the fuel pump in your Chevy truck requires some basic steps and a few special tools.
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Things You'll Need
- Floor jack
- Jack stands
- Hand siphon pump
- Gas cans
- Screwdrivers
- Fuel line wrench (if applicable)
- Socket set
- Hammer
- Drift punch
- Carburetor cleaner
- Rags
- Electric fuel pump
- Gasket scraper
- Pencils
Instructions
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Newer Pumps
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1
Place the vehicle in park or neutral with the emergency brake set. Raise the hood and disconnect the negative battery cable with a socket. Disconnect the gas filler cap and insert the hose of a hand siphon pump down the filler neck. Turn the crank handle on the siphon pump to remove all the fuel, emptying it into certified gas cans. Remove the fuel pump relay from the main fuse box; refer to your owner's manual for its location.
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2
Locate the Schrader valve on the fuel injection rail. It looks like a tire valve stem and has small cap on it. Remove the cap and depress the valve with a fingertip to relieve the fuel system pressure. Raise the vehicle with a floor jack and place two jack stands under the front frame and two under the rear frame. Slide under the rear of the truck and remove the hose clamp to the fuel filler hose neck. Pull the hose back.
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3
Use a socket and wrench to loosen and remove the fuel tank holding straps. Have an assistant help guide the tank down just far enough to access the the top connection on the fuel pump flange. Remove the hose clamps to the fuel vent line and the output fuel line with a screwdriver. Use a fuel line wrench to disconnect the output fuel line, if connected in this fashion. Unsnap the wire jack from its connector. Have your assistant lower the tank. Pull the tank out into the open.
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4
Use a hammer and drift punch to knock the fuel pump locking ring counterclockwise on the top fuel pump flange until it aligns with the notches. Pull the fuel pump assembly straight up and out. Clean the gasket surface on the fuel pump mounting surface with carburetor cleaner and a rag. Replace the gasket now, if you have a kit gasket. Place the new pump and assembly down inside the tank. Align the locking ring notches and use a hammer and drift punch to knock the ring tight in a clockwise direction.
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5
Have your assistant raise the tank with the floor jack high enough to make the top connections. Reconnect the output fuel line and tighten its clamp with a screwdriver, or line wrench, if so equipped. Snap the wire connector back together. Reconnect the fuel vent hose and tighten its clamp with a screwdriver. Have your assistant raise the tank up against the truck bed, while you align and screw in the strap bolts by hand. Tighten the bolts with a socket and wrench.
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6
Slip the fuel tank intake hose over the tank neck. Tighten the hose clamp with a screwdriver. Go to the fuse box and insert the fuel pump relay into its socket. Reconnect the negative cable with a socket and wrench. Turn the ignition on and wait for the engine to start.
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7
Refer to your owner's manual for the location of the mechanical fuel pump on your Chevy truck. Most bolt to the front of the engine on the passenger side. Loosen the hose clamps on the intake and output fuel line. Pull the hoses free and plug the ends with pencils. If the fuel lines have metal cap nut connectors, loosen them with a fuel line wrench and plug both insides of the fuel lines with a rag. Loosen and remove the two fuel pump mounting bolts and pull the pump off.
Older Pumps
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8
Locate the mechanical fuel pump on your Chevy truck, refering to your owner's manual if necessary. Most bolt to the front of the engine on the passenger side.
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9
Loosen the hose clamps on the intake and output fuel line. Pull the hoses free and plug the ends with pencils. If the fuel lines have metal cap nut connectors, loosen them with a fuel line wrench and plug both insides of the fuel lines with a rag. Loosen and remove the two fuel pump mounting bolts and pull the pump off.
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10
Use a gasket scraper to remove the old gasket material from the block mating surface. Clean the area with carburetor cleaner and a rag. Install the new fuel pump on the block. Start the bolts in by hand. Tighten the bolts with a socket and wrench. Push both fuel lines back on their connection nipples and tighten their hose clamps with a screwdriver. Use a fuel line wrench for metal cap nuts. Reconnect the negative battery cable and start the engine.
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1
Tips & Warnings
Some model Chevy trucks require you unscrew the two bolts holding the fuel pump to the screen and tank float assembly. Connect your new fuel pump onto your old assembly and drop it down into the tank.
Some Chevy model trucks have the fuel pump mounted on top of the tank midway under the chassis frame. You can access it by disconnecting the wire jacks to the taillight assembly and removing the truck bed bolts. You can then slide the truck bed back a few feet to gain access to the top of the gas tank.
You can remove the mounting bolts on an externally mounted fuel pump (some Chevy models) bracketed to the top of the tank and replace it without disrupting the screen and tank float assembly.
References
- Photo Credit panne image by Charly from Fotolia.com
