How to Repair a Chevy Suburban Fuel Pump
Most models of the Chevy Suburban use an electric fuel pump that is installed with the fuel sending unit within a module. You cannot replace the pump itself (as an individual component), but it is possible to replace the sending unit in the module or transfer it to a new pump module. This module is installed directly within the fuel tank. The repair process can vary, depending on the Suburban's exact year.
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Things You'll Need
- Wrench
- Floor jack
- Jack stands
- Screwdriver
- Transmission jack or wood block
- Locking pliers
- Needle-nose pointer
- Needle-nose pliers
Instructions
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Removal Procedure
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1
Remove the fuel pump's relay from the engine's fuse box, then run the engine until it stalls to relieve the fuel pressure. Disconnect the negative battery cable.
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2
Raise the Suburban's rear end onto jack stands, then unbolt and remove the tank shield, using a wrench, if needed.
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3
Disconnect the fuel supply and return lines by squeezing their quick-connect fittings, then loosen the hose clamps for the fill and vent hoses, using a screwdriver, and disconnect the hoses from the tank.
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4
Raise a transmission jack under the tank (a floor jack can also work if you put a block of wood on top) and unbolt the tank's straps, using a wrench. Lower the jack with the tank and disconnect the electrical connectors from the pump module flange.
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5
Loosen the pump's retaining ring, using large locking pliers as you push, and release the locking tab within the ring, using a needle-nose pointer tool.
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6
Pull the pump module out of the tank by the flange. If you are not replacing the module, make sure you don't damage the module's float mechanism.
Repair Procedure
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7
Disconnect the electrical connector to the sending unit from the module -- grip this connector with needle-nose pliers.
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8
Remove the retaining clip from the sending unit, using the pliers, then pinch the unit's tabs together with the pliers and remove the unit from the module.
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9
Connect the new sending unit to the pump module (or the old unit for a new pump module), inserting the retaining tabs into the square bracket. Connect the retaining clip with the pliers and plug in the electrical connector.
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10
Insert the module back into the tank, making sure the fittings for the fuel lines point in the same direction that they did previously. Screw in the retaining ring, using the pliers.
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11
Lift the tank into position, connect the electrical connectors and fuel lines, then bolt the straps into position. Reconnect the filler and vent hoses with their screw-based hose clamps.
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12
Reconnect the negative battery cable and the fuel pump fuse. You may need to turn the ignition switch to the "On" and "Off" positions back and forth to help re-pressurize the fuel system.
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