How to Install a Fuel Pump for a 2000 Chevy Pickup
Installing an electric fuel pump on a 2000 Chevy pickup requires access to the top side of the fuel tank. The fuel pump slides through a hole on the top of the tank, where it mounts internally. The real challenge to installing a fuel pump is gaining access to the top of the gas tank without damaging the existing fuel lines. There are several ways to gain access to the Chevy's gas tank, and cutting an access hole through the truck bed.
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Things You'll Need
- Safety glasses
- Floor jack
- Jack stands
- Wheel blocks
- Wrench set
- Penetrating oil
- GM fuel line tools
- Fuel Pump ring tool
- Brass punch
- Screwdriver set
- Shop towels
- Deep well socket set
- Hammer
- Air wrench
- Approved gas container
- Hand tools
Instructions
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The Truck Bed Removal Method
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1
Remove the negative battery terminal from the battery, the battery is located under the hood and may have plastic caps over the terminals.
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2
Lower the tailgate. Pull up on the two tailgate folding straps located on both sides of the tailgate, and align the slot in the tailgate brackets with the T-pin mount and remove the folding straps. Lower the tailgate until the slot in the tailgate hinge cap aligns with the hinge mount and slide the tailgate out and remove it from the pickup bed.
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3
Locate and remove the eight bolts that hold the pick up truck bed to the truck frame. Using an air wrench or a socket set to loosen the bolts.
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4
Unplug the light wire plug located in the rear near the tailgate mount. Remove the three screws in the filler neck. The filler neck is located under the fuel door.
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5
Lift the truck bed up on the fuel door side and place a jack stand on top of the frame to prop the bed up high enough to gain access to the top of the fuel tank. The bed can be lifted completely off the frame and placed on two saw horses, with enough people to lift it.
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6
Brush the top of the tank clean with an old snow brush or old broom. Take care not to damage the fuel lines or wiring.
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7
Match the fuel pump plug with the plug wired to the truck, the truck plug often times must be replaced with the plug provided with the new fuel pump. The plug must be wired as per the instructions provided with the fuel pump and should be wired before unsealing the original fuel system.
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8
Remove the fuel lines from the top of the fuel pump. This requires the special fuel line removal tools, they are very inexpensive and three different sizes maybe required.
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9
Remove the fuel pump retainer ring with the fuel pump ring tool or rotate the ring by using a brass punch and a hammer. Lift the fuel pump assembly out of the hole. Use shop rags to clean up any spilled fuel.
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10
Install the new fuel pump by inserting it in the hole seating it against the rubber O-ring. Replace the fuel pump retaining ring, rotate the ring using the tool or a hammer and brass punch until it is locked down. Plug in the pump and replace the lines, by sliding them back onto the pump. Reinstall the negative battery terminal and start the vehicle. If the pump operates as it should shut off the vehicle.
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11
Replace the truck bed and tailgate by reversing the steps used to remove them.
Tank Removal Method
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12
Remove the negative terminal from the battery, the battery is located under the hood. Drain as much gasoline out of the tank and into an approved fuel container, to reduce the weight of the gas tank. Use a pump, do not siphon.
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13
Place a floor jack under the center of the rear differential and jack up the truck. Insert two jack stands one near each wheel under the frame.
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14
Slide under the truck and spray the two threaded gas tank strap rods with penetrating oil. Use a deep well socket to loosen and remove the two straps. Sometimes the straps are rusted and must be handled with care to prevent breaking them. Remove the gas tank shield if applicable.
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15
Lower the gas tank far enough to gain access to the fuel lines. Use the GM fuel line tool to remove the fuel lines, and unplug the fuel pump. Slide the tank out from under the tank. Clean off the top of the tank.
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16
Remove the fuel pump ring using the fuel pump ring tool or rotate it clockwise with a hammer and brass punch. Lift the pump out of the tank and replace with a new one.
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17
Slide under the truck and be sure the pump plug matches the new fuel pump, if not wire the new plug to the truck as per the specific instructions included with the new fuel pump.
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18
Replace the tank by reversing the steps used to remove it.
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1
Tips & Warnings
A shop vacuum works well to clean the dirt and debris from the top of the fuel tank if one is available.
Complete all fuel pump plug wiring before removing the lines or the pump. Do not cut corner when wiring the new fuel pump plug.
In most cases the fuel pump ring should be rotated clockwise to remove and counterclockwise to install.
Always wear eye protection when working in or around automobiles.
Gasoline is a known irritant; avoid all contact with skin.
Do not permit any smoking in or around the fuel pump repair area.
Remove any jewelry such as watches and bracelets.
Do not use a steel punch to rotate the ring as it may create a spark
Frequently touch the metal frame away from the fuel pump opening to discharge any static electricity.
Turn off shop furnaces and temporarily extinguish all pilot lights in the shop near the fuel pump repair area.
References
- Photo Credit gas tank image by Mat Hayward from Fotolia.com
