How to Change the Fuel Pump in Chevrolet Cars

by Contributing Writer; Updated June 12, 2017

An Chevrolet car fuel pump forces gasoline from the tank to the engine. It works electronically and the constant flow of the current eventually wears out the pump. Clogged fuel filters, which force a higher current, can speed up the pump's wearing-out process. Overheating also contributes to wearing out the pump, especially when you keep the fuel tank near empty. A broken fuel pump prevents the car from running, while a worn pump reduces fuel flow. You can replace the pump from the fuel-sender access panel in the vehicle's trunk.

Under The Hood:

 How to Change the Fuel Pump in a 3.8L Chevy Impala

Removing the Fuel Pump

Park your Impala on level ground in a well-ventilated area and open the hood.

Remove the sight shield from the top of the engine using a ratchet and socket, if equipped.

Loosen the fuel tank filler cap and disconnect the ground (black) battery cable with a wrench.

Locate the Schrader valve at the beginning of the fuel feed pipe on the fuel rail. This is the rail that feeds the fuel injectors. The valve is similar to the air valve on your Chevy tires.

Wrap a shop rag around the Schrader valve and depress the inside stem with a flat-head screwdriver. Use the rag to catch the fuel that will come out of the valve. After that, replace the sight shield to the top of the engine.

Take the spare tire and other items from the trunk of your Impala.

Remove the carpet from the trunk.

Unfasten the nuts from the fuel sender/pump access panel on the floor of the trunk and remove the access panel. Use a ratchet and socket.

Unplug the fuel tank pressure sensor and fuel sender from the assembly through the access hole.

Disconnect the hoses from the fuel sender/pump assembly. On hoses with plastic connectors, press the tabs and pull the hose from its fitting. On hoses with metal connectors, use tool set J 37088-A.

Rotate and unlock the retaining ring holding the fuel sender/pump assembly to the fuel tank using a drift punch and a hammer.

Lift the retaining ring and fuel sender/pump assembly out of the fuel tank. Locate the large O-ring seal between the fuel tank and the assembly and discard the O-ring.

Remove the fuel pump from the assembly using a pair of needle-nose pliers and a flat-head screwdriver.

Installing the New Fuel Pump

Mount the new fuel pump on the assembly using the pair of needle-nose pliers and flat-head screwdriver. Swing the float arm on the assembly and make sure the pump strainer is not in the arm’s way. Adjust it, if necessary.

Place a new assembly O-ring seal.

Insert the fuel sender/pump assembly into the fuel tank and verify that the pump strainer is not twisted. Then rotate the retaining ring with the drift punch and hammer to lock the assembly to the fuel tank.

Connect the hoses to the fuel sender/pump assembly by pushing the hose connectors against their fittings.

Plug the fuel tank pressure sensor and fuel sender to the assembly.

Tighten the fuel tank filler cap and connect the ground (black) battery cable using the wrench.

Turn the ignition to the “On” position for two seconds and then to the off for 10 seconds. Turn the ignition back to the “On” position and check for gas leaks around the tank.

Turn off the ignition.

Position the access panel in place and tighten the mounting nuts using the ratchet and socket.

Replace the carpet, spare tire and other items in the trunk.

Items you will need

  • Ratchet

  • Socket set

  • Wrench

  • Shop rag

  • Flat-head screwdriver

  • Tool set number J 37088-A

  • Drift punch

  • Hammer

  • Needle-nose pliers

  • New O-ring seal

 How to Replace a Fuel Pump in a Chevy Cobalt

Determine which fuel pump your Chevy Cobalt will need. This depends not only on the make and model, but also the engine size and type. A Chevy Cobalt may have one of the following engines: 2.0 L S/C LSJI4, 2.0 L Turbo LNFI4, 2.2 L L61I4, 2.2 L LAPI4 or 2.4 L LE5I4.

Prepare your vehicle for fuel pump servicing. Remove the fuel tank, and release the retaining tab on the fuel tank retainer. Release the electrical harness for the fuel tank from the retaining slot and disconnect the harness from the fuel tank pressure sensor.

Release the fuel pump retaining lock ring by carefully rotating it using tool J39765. Slide the ring over the fuel pump pipes and slowly raise the fuel pump until you can just see the float arm for the fuel level sensor. Empty the fuel in the pump reservoir into an approved container and remove the fuel pump.

Install the new fuel pump using the items included in the kit, especially the tank seal. Tilt the pump towards the back of the fuel tank to avoid bending the fuel level sensor float arm.

Install the fuel tank with the aid of an assistant as you tighten the fuel tank strap bolts to 18 ft. lbs with a torque wrench. Tighten the fuel filler hose to 40 in. lbs. with a torque wrench.

Items you will need

  • Fuel pump kit

  • Tool J39765

  • Torque wrench

 How to Replace a Fuel Pump in a Dodge Durango

Determine which fuel pump your Dodge Durango will need. This depends not only on the make and model, but also the engine size and type. Models made from 1998 to 2003 have a 4.7 L PowerTech, 5.2 L Magnum, or 5.9 L Magnum. Models manufactured after 2004 will have a 3.7 L Power Tech, 4.7 L Power Tech or 5.7 L Hemi.

Prepare your vehicle for fuel pump servicing. Drain and remove the fuel tank. Note the position of the indexing arrow on top of the fuel pump before removing it.

Remove the lock ring on the fuel pump using tool 9340 with a ½-inch drive breaker bar to rotate the lock ring counter-clockwise. The fuel pump should rise up slightly when you remove the lock ring. Remove the fuel pump using care not to bend the float arm.

Install the new fuel pump using the items included in the kit, especially the rubber gasket for the fuel tank. Rotate the fuel pump until the alignment arrow points toward the alignment mark. Be sure the fitting on top of the fuel pump faces towards the driver's side.

Tighten the lock ring with tool 9340 until all seven notches engage. Complete the installation by reversing Steps 2 and 3.

Items you will need

  • Fuel pump kit

  • Tool 9340 with ½-inch drive breaker bar

 How to Replace a Fuel Pump in a Ford Explorer

Determine which fuel pump your Ford Explorer will need. This depends not only on the make and model, but also the engine size and type. Models built from 1991 to 1994 have a 4.0 L engine while 1995 to 2001 models add the option for a 5.0 L Windsor engine. Models made from 2002 to 2005 may be equipped with the 4.0 L Cologne or 4.6 L Modular engine.

Prepare your vehicle for fuel pump servicing. Position your vehicle on a hoist and place it in neutral. Release the fuel system pressure and drain the tank. Remove the fuel tank skid plates with a socket wrench and use a jack to support the fuel tank. Take out the strap bolt for the fuel tank with a socket wrench, remove the fuel tank and disconnect the vapor tube fitting.

Release the fuel pump retaining lock ring by carefully rotating it using the fuel pump locking ring tool. Remove the lock ring first followed by the fuel pump. Use care to avoid damaging the fuel filter and float arm. Discard the old O-ring seal.

Install the new fuel pump using the items included in the kit, especially the new O-ring seal.

Complete the installation by reversing the removal procedure.

Items you will need

  • Fuel pump kit

  • Jack

  • Socket wrench set

  • Fuel pump locking ring tool

 How to Replace a Fuel Pump in a Saturn Ion

Determine which fuel pump your Saturn Ion will need. This depends not only on the make and model, but also the engine size and type. This model is available with a 2.0 L LSJ supercharged, 2.2 L l61 and 2.4 L LE514 engine.

Prepare your vehicle for fuel pump servicing. Relieve the fuel system pressure and disconnect the negative battery cable with a socket wrench. Disconnect the fuel tank by removing the fuel tank strap bolts with a socket wrench.

Disconnect the fuel lines and hoses from the fuel pump. Remove the retaining ring for the fuel pump with sending unit wrench J43827 and disconnect the retaining clip by pulling it toward the float arm and lifting up.

Pull the fuel pump out of the fuel tank and discard the old fuel tank seal. Remove the feed line from the fuel pump with clamp pliers J43914 and unplug the fuel pump's electrical connector.

Install the new fuel pump using the items included in the kit and be sure to replace the fuel tank seal.

Complete the installation by reversing the removal procedure and tighten the bolts on the fuel tank strap to 18 ft. lbs. with a torque wrench. Start your vehicle to check for leaks.

Items you will need

  • Fuel pump kit

  • Clamp pliers J43914

  • Sending unit wrench J43827

  • Socket wrench set

  • Torque wrench

 How to Change the Fuel Pump on a Cavalier

How to Change the Fuel Pump on a Cavalier

Park your vehicle on a level parking space, and disconnect the positive terminal of the car battery. You do this by using a wrench to loosen the battery terminal bolt.

Siphon the gas tank. To do this, open the gas tank door and insert the siphon into the gas tank. Place the other end of the siphon into a gas can. You can purchase siphons at any auto parts store. Be sure to follow the directions that come with your siphon. Make sure the gas can is big enough to hold the amount of gas that is in your car, because once the siphoning process starts it will not stop.

Back your car up onto two mechanic's ramps. This will allow you to get under the car comfortably so you can pull the fuel pump.

Lay down on a crawler facing up and roll underneath the back of the car until you reach the gas tank. The tank will be a large, black plastic tub located underneath the backseat of the car.

Locate the two metal straps that hold the gas tank up and trace these back to where they are bolted to the car.

Use a socket wrench with an extension to remove the bolts. The gas tank will start to fall as you remove the bolts. Since it is empty is should be light enough to set on the floor or on your chest if the tank won't reach the floor because of wires.

Disconnect the fuel lines and wire harness by pushing the white buttons on the fuel lines and wire harness.

Pull gas tank out from underneath the car. Clean the debris off the top of the gas tank.

Remove all the bolts that are holding the fuel pump to the gas tank. You will know it is the fuel pump because the top of the pump will be a cylinder with two tubes coming out of it.

Gently free the fuel pump from the fuel tank, being careful not to allow any debris to fall into your gas tank. Hold up the gas pump and on the end is a sock that needs to drain. Place pump out of the way. Clean the hole in the gas tank, scraping the edges to remove debris.

Take the new fuel pump and place it in the hole where the old pump was. Bolt the new pump into place on the gas tank.

Slide the tank underneath the car and position it where it should go. Reconnect the wire harness and two fuel lines. Place a jack underneath one side of the fuel tank and go to the other side of the fuel tank to tighten the metal straps and insert bolts. Tighten all bolts at the fuel tank.

You can add the fuel you took out of the fuel tank earlier and pour it back into your car using the canister. Reconnect the positive battery terminal and drive off the ramps.

Items you will need

  • Level parking space Wrench Siphon Fuel canister for short storage Mechanic's ramps Crawler Socket wrench and extension New fuel pump

 How to Replace the Fuel Pump in a 2004 Chevrolet Cavalier

Prepare the Car

Raise the rear end of the car using ramps or jack stands. Chock the front wheels to prevent it from rolling off of the supports.

Remove pressure from the fuel lines. The easiest way to do this is to remove the fuel pump relay in the engine compartment fuse box. Once the relay is out, start the vehicle and let it use the rest of the fuel in the system.

Disconnect the negative battery cable to prevent the system from accidentally powering and possibly igniting fuel. Wrap the negative cable with tape to prevent accidental connection.

Siphon the fuel to reduce the amount to 1/4-tank or less.

Remove the Fuel Tank

Disconnect the rubber hangers on the exhaust system by removing the bolts securing them to the underbody of the car. Allow the exhaust pipe to rest on the back axle.

Disconnect the fuel filter hose and the EVAP line by unhooking the connectors, pushing the connectors out of their holders and pulling off the hoses. Disconnect the fuel filler neck by loosening the clamp and removing the hose.

Support the fuel tank with a jack stand to prevent it from falling on the floor.

Remove the straps holding the tank in place and disconnect the heat shield by bending it to remove it from the rivet holding it to the underbody of the car.

Remove the Fuel Filter

Lower the tank far enough to reach in and disconnect the electric lines from the pump. Finish lowering the tank to the ground.

Remove the pump lock nut with a pair of water pump pliers to free the fuel pump from the tank. If the pliers do not work, use a piece of wood or a brass punch and a rubber mallet (to prevent sparks) to strike the lock nut in a counterclockwise direction.

Remove the pump by pulling it out of the tank. Make sure the fuel drains from the pump before it spills over the floor. Make sure the electrical connector from the old pump matches the new pump. If they are not compatible, check if the new pump came with a wiring harness and change it. If there is no harness, exchange the connector on the pump itself with the connector on the new pump.

Replace the O-ring before installing the new pump.

Install the new pump by following the removal steps in reverse order.

Items you will need

  • New fuel filter

  • Water pump pliers

  • Rubber mallet

  • Wrench set

  • Jack stands

  • Wheel chocks

 How to Replace the Fuel Pump on a Chevy Lumina

Position a floor jack under the right-rear jacking position, located under the body of the car, just a few inches in front of the rear wheel opening; lift the right-rear of the car until the wheel is off the ground. Place a jack stand under the rear axle, near the wheel, and lower the car onto the jack stand. Loosen the clamps that attach the rubber filler tube and vent tube to the fuel filler neck. Disconnect the rubber filler tube and vent tube from the fuel tank.

Disconnect the negative battery cable from the battery. Drain the tank by siphoning the fuel out of the filler neck vent tube into an approved container like a gas can--use a siphon hose designed for gasoline.

Separate the fuel lines that lead to the fuel tank by squeezing the quick disconnect tabs together while pulling with a twisting motion. Disconnect the vapor tube tube by twisting the rubber connector while pulling the plastic line out of it.

Remove the rubber exhaust hangers by prying them off the steep pin they are attached to, so as to allow the exhaust to drop out of the way. Push the exhaust to the driver side of the car.

Support the tank, using a floor jack with a piece of wood on top, and remove the 15 mm gas tank strap bolts. Lower the gas tank slightly and disconnect the fuel pump wiring harness from the top of the fuel tank. Lower the tank completely and slide it out from under the car.

Clean the debris and dirt from the top of the fuel tank. Remove the pump assembly by rotating the locking ring counter-clockwise and pulling the assembly from the tank. Insert the new fuel pump assembly into the tank and lock it into place with the locking ring.

Slide the fuel tank back under the car and lift it into place using the floor jack. Plug the electrical connector into the top of the pump assembly. Attach the tank straps and tighten the strap bolts, in order to secure the tank to the car. Slip the filler hose and vent hose into place and tighten the clamps securely. Reattach the negative battery cable. Fill the tank with gas and start the engine. Check for leaks before lowering the Lumina to the ground and test-driving it.

Items you will need

  • Wheel chocks

  • Floor jack

  • Jack stands

  • Siphon hose

  • Gas can

  • Socket set

  • Wrench set

  • Screwdriver set

  • Hammer

  • Punch

 How to Replace the Fuel Pump on a 2005 Chevrolet Malibu

Fuel Tank Removal

Kick wheel chocks in front of the front tires. Lift the rear of the Malibu with a floor jack and slide jack stands under the rear suspension crossmember. Lower the vehicle onto the jack stands.

Find the fuel pump wiring harness on the upper, front part of the fuel tank. Unplug the wiring harness. Unscrew the gas cap from the vehicle to relieve the tank pressure. Start the Malibu’s engine and allow it to idle until it stalls. Crank the vehicle for an additional three seconds to relieve any residual pressure.

Connect a memory saver to the vehicle, using the memory saver’s instructions as your guide. Loosen the negative battery cable with a combination wrench and pull it from the battery. Set the cable aside to prevent inadvertent reconnection.

Insert a fuel siphon with a semi-rigid siphon hose into the fuel filler hose. Feed the siphon hose downward until you feel it contact the bottom of the fuel tank. Place the siphon’s drain hose into a 5-gallon fuel storage tank. Siphon the fuel from the tank, using the siphon’s pump. When the fuel storage container fills, release the vacuum from the siphon and transfer the drain hose to a new container, then restart this step.

Remove the siphon from the fuel filler hose once you cannot siphon any more fuel from the tank.

Crawl under the vehicle. Unplug the evaporative emissions vent valve solenoid’s wiring harness, which you can find on the rear, driver’s side of the fuel tank. If the vehicle has rear antilock brakes, pull the ABS wiring harness from the side of the evaporative emissions canister on the driver’s side of the fuel tank.

Move to the passenger’s side of the vehicle and find the fuel-and-brake line bundle. Squeeze the plastic ears on the quick connect fitting on each fuel pump line and pull each line away from the pump-to-engine lines. Wrap a thick shop cloth around the now open ends of the tank-to-engine fuel lines.

Loosen the hose clamp securing the rubber end of the fuel filler hose to the fuel tank, using a ratchet and socket. Pull the fuel filler hose from the tank with a slight twisting motion. Pull the vapor recirculation line -- the rubber hose that runs along the fuel filler hose – from its inlet on the fuel tank.

Position a jack stand under the muffler. Press all of the underbody rubber exhaust hangers from the exhaust system. Lower the exhaust until the muffler rests out of the fuel tank’s way, on the jack stand.

Instruct an assistant to hold upward pressure on the fuel tank to prevent it from falling. Remove the bolts securing the left side fuel tank straps, using a ratchet and socket, then the right side straps.

Lower the passenger’s side of the fuel tank first, with the aid of an assistant, to clear the exhaust system. Allow the tank to clear the passenger’s side frame rail, then move the tank toward the front, passenger’s side of the vehicle as you lower it from the vehicle. Pull the tank from under the vehicle.

Fuel Pump Removal

Unplug the wiring harness and disconnect the ventilation hose from the fuel pump.

Turn the fuel pump’s locking ring counterclockwise with a ratchet and 130 mm lock ring – GM part No. J-45722 – while your assistant holds the tank from spinning. Don’t be alarmed if the fuel pump module jumps upward slightly when you remove the ring, this is normal.

Lift the fuel pump module just enough to access the fuel tank ventilation connector on the underside of the fuel pump’s upper plate. Squeeze the ears on the quick disconnect fitting and unplug the ventilation connector. Remove the fuel pump assembly from the tank.

Pull the old O-ring off the fuel pump’s mounting hole on the tank, using a flat-head screwdriver.

Fuel Pump Installation

Install a new O-ring, which comes with the new pump, onto the fuel pump’s mounting hole in the tank.

Guide the fuel pump module into the tank and before completely seating it, connect the fuel tank’s ventilation hose to the underside of the pump’s upper plate. Press the ventilation tube upward until its quick-connect fitting snaps into place.

Lower the fuel pump module into the tank. Press downward on the fuel pump to until the modules upper panel is flush with the top of the tank. Sit the locking ring over the fuel pump, so its tabs align with the notches in the tank. Rotate the locking ring clockwise until it seats on its second stop – you will feel it click twice, the second click is its second stop.

Connect the wiring harness to the fuel pump and plug the ventilation hose to its outlet on top of the fuel pump.

Fuel Tank Installation

Slide the tank under the vehicle and with the aid of an assistant, lift the driver’s side of the tanks over the exhaust. Lift the passenger’s side of the tank upward, so it is just inside of the right side frame rail. Verify that you did not pinch the fuel pump wiring harness or fuel feed lines.

Instruct the assistant to hold the tank in place as you install the tank straps and hand-tighten their retaining bolts. Tighten the strap bolts to 15 foot-pounds, using a torque wrench and socket.

Tell your assistant to lift and hold the exhaust system, as you press the rubber hangers back onto their respective exhaust arms.

Connect the fuel pump’s main power wiring harness to the Malibu’s wiring harness

Press the fuel filler hose onto the inlet on the fuel tank and tighten its hose clamp to 35 inch-pounds, using an inch-pound torque wrench and socket. Press the vapor recirculation line into its inlet on the fuel tank.

Remove the shop cloths from the fuel pump-to-engine lines and press them into their respective fuel pump lines until you hear the quick connector snap into place.

Plug the evaporative emissions vent valve solenoid’s wiring harness tot eh Malibu’s wiring and press the ABS wiring harness back into place on the evaporative emissions canister, if applicable.

Raise the vehicle off the jack stands and remove the jack stands. Lower the Malibu to the ground. Reconnect the negative battery cable to the battery and tighten its retaining bolt to 13 foot-pounds.

Remove the memory saver. Tighten the gas cap until it clicks three times. Turn the ignition to the “Run” position for two seconds, then to the “Off” position for 10 seconds. Turn the ignition back to the “Run” position and check for fuel leaks from under the vehicle. Start the engine and verify that it idles normally. Shut the engine off.

Items you will need

  • 3 jack stands

  • Floor jack

  • Memory saver

  • Combination wrench set

  • Fuel siphon with a semi-rigid siphon hose

  • 5-gallon fuel storage tanks (amount varies)

  • Ratchet

  • Socket set

  • Thick shop cloths

  • 130 mm lock ring tool (GM part No. J-45722)

  • Flat-head screwdriver

  • Torque wrench

  • Inch-pound torque wrench

 How to Replace the Fuel Pump for a 2001 Impala

Park the car and turn off its ignition. Put on rubber gloves.

Lift and prop up the vehicle's hood.

Locate the Impala's battery in the engine compartment. It is a rectangular box with a cover. Remove the cover.

Locate the battery's negative terminal, identified by a "-." Use the 1/2-inch wrench to unscrew the nut at the negative terminal. Remove the the battery cable from the negative terminal.

Locate the top fuse block on the passenger's side of the engine compartment. Remove the fuel pump fuse, which is the top, left horizontal fuse.

Open the fuel compartment on the driver's side of the vehicle, located toward the back.

Unscrew the fuel cap to relieve the tank's pressure.

Open the trunk.

Locate the fuel sender access panel in the floor of the trunk. Unscrew the panel's bolts with the socket wrench.

Remove the panel to expose the fuel pump.

Unplug the fuel pump's electrical connectors.

Loosen the clamp on the fuel line that connects to the pump, using a wrench, and disconnect the fuel line from the pump. Some fuel may spill out.

Remove the fuel pump.

Place the new fuel pump into the space below the panel.

Connect the fuel line to the new pump. Securely tighten the line's clamp.

Plug in the pump's electrical connectors.

Replace the panel and screw in its bolts. Close the trunk.

Replace the fuel tank cap. Replace the fuel pump fuse, reconnect the battery's negative terminal and replace the battery compartment cover. Close the vehicle's hood.

Items you will need

  • 1/2-inch wrench

  • Fire extinguisher

  • Rag

  • Rubber gloves

  • Socket wrench

  • Replacement fuel pump

 How to Replace a Fuel Pump in a Chevy Avalanche

Select the new fuel pump for your Chevy Avalanche. You will not only need to know the make and model, but also the engine size. Models made from 2001 to 2006 may have a 5.3 L or 8.1 L engine and models made after 2006 can have a 5.3 L or 8.1 L engine.

Prepare your vehicle for fuel pump servicing. Drain the fuel tank and disconnect the negative battery cable with a socket wrench.

Relieve the fuel system pressure. Loosen the fuel filler cap and connect a fuel pressure gauge to the fuel pressure valve. Wrap a shop towel around the fitting and place the bleed hose into an approved container. Bleed the fuel pressure and remove the fuel tank.

Disconnect the electrical connection from the fuel pump and turn the locking ring on top of the fuel tank counterclockwise to release the pump. Pull the fuel pump assembly out of the tank.

Install the new fuel pump and secure it by turning the locking ring clockwise. Install the fuel tank and refill it. Attach the negative battery cable. Run the engine and check for leaking fuel.

Items you will need

  • Fuel pressure gauge

  • Fuel pump kit

  • Shop towel

  • Socket wrench set

 How to Replace a Fuel Pump in a Geo Tracker

Choose a new fuel pump for your Geo Tracker. This will require you to know the make and model, engine size and engine type. Models made from 1989 to 1998 have a 1.6 L engine, and a 2.0 L engine was added for models made after 1998.

Prepare your vehicle for fuel pump servicing. Release the fuel system pressure, disconnect the negative battery cable and safely raise your vehicle. Drain the fuel tank and remove its connections. Remove the fuel tank mounting fasteners with a socket wrench and lower the fuel tank from the underside of your vehicle.

Remove the retaining bolts from the fuel pump with a socket wrench and lift the fuel pump out of the fuel tank. Discard the old gasket.

Install the new fuel pump using the items included in the kit, especially the gasket. Align the holes for the retaining bolts and push the fuel pump into the tank. Install the retaining bolts and tighten them securely.

Complete the installation by reversing the removal procedure. Tighten the fuel tank mounting fasteners to 36.5 ft. lbs. with a torque wrench.

Items you will need

  • Fuel pump kit

  • Socket wrench set

  • Torque wrench

 How to Replace the Fuel Pump on a 1996 Chevy Truck

Drain the fuel tank by using a siphon or running the vehicle until the fuel is expended. The tank will need to be removed, and a lighter tank is far easier to take out than one half full of gasoline.

Disconnect the battery at the positive terminal post by turning it counterclockwise and pulling it from the post. This shuts off any possible electrical current that could cause injury.

Lift the truck with the floor jack and place the rear frame rails onto the jack stands. Remove the rear wheels by turning all of the lug nuts in a counterclockwise direction and pulling the wheel from the hub. You do not have to remove the wheels, but it allows easier access to the system and fuel tank.

Disconnect the gas tank and fuel pump's electrical and hose connections. There are two or three hoses (depending on the model) and an adapter plug located in the upper-front area of the tank. Pinch the hose clamps with a pair of pliers and pull the hoses from the plastic nipples. They are sized and don't need to be marked. Pull the adapter plug out of the socket by disengaging the small catch clip on the top and tugging firmly on the plug. Some fuel may come out when pulling the hoses, so be sure to have the drain pan handy.

Unbolt the fuel tank shield plate by turning all of the mount bolts around the edges counterclockwise. Set the plate and bolts aside. Disconnect the filler neck at the body, where the neck meets the outer hole. There are usually three screws here that can be turned counterclockwise.

Place the floor jack head underneath the fuel tank for support, then turn all of the tank's mount bolts counterclockwise. As the bolts come out, the tank will drop. Pumping the floor jack to keep the tank positioned will allow the last of the bolts to be removed. Lower the tank out of the truck with the floor jack, and move it to a work area.

Remove the fuel pump from the top of the tank by turning all of the screws counterclockwise. Once the screws are out, the 1-foot-long pump pulls vertically out of the hole. Replacement is the reversal of the removal process.

Items you will need

  • Socket set

  • Wrenches

  • Pliers

  • Screwdrivers

  • Drain pan

  • Floor jack

  • Jack stands

  • Lug wrench

 How to Change the Fuel Pump on a 1993 Chevy Pickup

Raise the rear of the truck using the floor jack. Support it using the jack stands for safety. Place the jack stands under the frame so as not to interfere with the removal process.

Drain the fuel tank into a fuel container if it is over half full. Jump the fuel pump relay by placing a jumper wire in the battery positive terminal of the relay and the other end of the jumper in the fuel pump terminal. The pump will run continuously until the jumper is removed. Remove the cap on the fuel rail Schrader valve. This looks like an air valve on a tire, but is located under the hood and on the top of the fuel injector metal supply line. Use the valve stem retractor and remove the Schrader valve. Place a rag over the valve while removing it to capture the small quantity of fuel expelled.

Place the rubber hose over the Schrader and run it over the fender and into a fuel container. Remove the cover on the fuse/relay box on the driver's side fenderwell. Locate the fuel pump relay from the diagram on the fuse block cover and remove it.

Check the terminals with the voltmeter by connecting the black lead on the voltmeter to a solid ground. Probe the terminals in the fuse block vacated by the four-pronged relay using the red lead. Probe each of the four female terminals in search of the one with battery voltage. Make a note of this terminal. Turn the voltmeter dial to ohms and probe the remaining terminals for a good ground. The ground will be the terminal leading to the fuel pump. Jump the battery terminal and this ground terminal with a jumper wire. The fuel pump will come on and pump the fuel out the Schrader and into the fuel container.

Remove 8 gallons to be on the safe side. To stop the fuel flow just unplug the jumper wire. When finished, remove the jumper wire and plug the relay in. Remove the fuel hose from the Schrader and replace the valve in the Schrader and the cap.

Unplug the fuel pump electrical connector at the backside of the fuel tank. Loosen the hose clamps on the top and bottom of the fuel filler hose with a screwdriver. Remove the hose. Loosen the fuel vent hose clamp at the fuel tank and pull it off. The fuel vent hose parallels the filler hose.

Place the floor jack under the fuel tank and between the two fuel tank straps. Remove the two tank-retaining strap bolts, using a 15-mm socket. Carefully lower the fuel tank sufficiently to access the top of the tank to remove all the hoses from the top of the fuel pump cap. These are quick disconnect fittings. Pinch the connectors and pull them off. There should be three connectors.

Lower the fuel tank to the ground and pull it from under the truck to facilitate the removal of the pump. Remove the nuts in the lock-ring, surrounding the fuel pump cap plate using the appropriate-sized socket. Withdraw the fuel pump and fuel level sending unit from the fuel tank.

Unplug the electrical connector on the fuel pump. Unsnap the plastic clamp around the fuel hose on the fuel pump and pull the pump out of the hose. Insert the fuel pump into the fuel hose and pinch the clamp around the hose. Plug the electrical connector back into the fuel pump.

Install the fuel strainer (filter) on the bottom intake of the fuel pump. Make sure that the strainer is oriented in the same direction as the old pump and that the strainer does not interfere with the fuel level sending unit operation. Install a new O-ring on the fuel pump-sealing surface on the tank. Install the fuel pump/fuel level sending unit into the tank. Bend the fuel strainer up to get it through the hole in the tank. Make sure the fuel line fittings are facing in the proper direction.

Position the lock ring over the studs in the tank. Screw in the bolts and tighten them securely with a socket. Position the fuel tank on the floor jack and raise it up enough to connect the three fuel lines. Plug in the electrical connections.

Raise the tank until it touches the floor of the vehicle. Bring the straps around the bottom of the tank. Insert the bolts through the straps, then thread them into their threaded receptacles. Tighten the bolts. Install the filler hoses and the vent hoses. Tighten the clamps.

Items you will need

  • Floor jack

  • Jack stands

  • Ratchet

  • Set of sockets

  • Common screwdriver

  • Voltmeter/Ohmmeter

  • 6-foot length of 5/16-inch fuel line

  • Schrader valve extractor

  • Jumper wire with a spade terminal on both ends

 How to Change a Fuel Pump on a 2001 Suburban

Removing the Fuel Pump

Park the truck on a flat surface. Ensure the parking brake is set.

Raise the hood of the truck to access the engine compartment. Locate the relay panel behind the battery. Pull the cover off the panel and locate the relay for the fuel pump. Pull the relay with your hands. Start the truck and allow it to run until it stalls.

Siphon the fuel out of the gas tank with a siphon kit. The siphon kit can be purchased at the local automotive-parts store. Allow the fuel to drain into a drain pan or into a gasoline can. The fuel will need to be poured back into the tank once the new pump assembly is installed.

Raise the back of the truck with a jack. Position the jack under the differential and raise the truck high enough to place a set of jack stands under the frame rail. Lower the truck onto the jack stands.

Locate the fuel tank underneath the truck, at the back of the truck. Place the jack under the fuel tank and raise it up to the fuel tank. This will support the fuel tank when the straps are removed.

Unbolt the two straps that hold the tank in position, using a socket wrench. Place the straps to the side.

Lower the tank slightly to access the fuel lines and electrical wires at its top. Disconnect the wiring by pulling the tabs up at the connectors and separating them. Pull the fuel lines off at the piping.

Disconnect the filler hose at the back of the fuel tank by loosening the hose clamp with a flat-head screwdriver. Pull the hose off the tank by hand.

Lower the tank to the ground. Slide the tank off the jack and out from under the truck.

Twist the ring at the top of the tank counter-clockwise to access the fuel pump. The ring will consist of plastic tabs that can be pushed out with a punch and a hammer. Strike the hammer to the punch until the ring is able to be turned by hand. Pull the ring off the top and place to the side.

Pull the fuel pump assembly out of the tank. The complete assembly will need to be replaced.

Installing the Fuel Pump

Position the new assembly into the fuel tank. Drop the assembly in the tank at an angle to prevent damage to the fuel-sending unit. The sending unit controls the gas gauge.

Replace the O-ring around the top of the tank. Remove the old one and slide the included O-ring in its place.

Tighten the ring back onto the fuel tank by hand. Tighten by tapping the ring in a clockwise motion with the punch and hammer.

Place the tank back onto the jack. Slide the tank under the truck. Raise the tank to connect the wires and fuel lines. Push the electrical connectors together. They will lock in place. Attach the fuel lines by pushing them onto the piping until they lock in place.

Push the filler hose on to the back of the tank. Tighten the hose clamp to secure the hose in place.

Raise the tank up to the truck. Tighten the straps to the frame to secure the fuel tank. Hand-tighten the bolts until all the bolts are set in place. Tighten them with the socket wrench to ensure the bolts are tight.

Slide the jack under the rear end. Raise the truck to pull the jack stands out from under the truck. Lower the truck to the ground.

Pour the fuel back in to the fuel tank. Plug the fuse back into the fuse panel. The truck is ready to start.

Turn the ignition to the "Start" position. Hold the ignition in that position for five seconds. This will prime the fuel pump. Turn the key and allow it to start. There may be air in the fuel lines, so it may not start right away; once the air is evacuated, the truck will start up.

Allow the truck to run for five minutes. Observe for any leaks.

Items you will need

  • Chock

  • Siphon kit

  • Drain pan

  • Jack

  • Jack stands

  • Socket wrench

  • Socket set

  • Flat-head screwdriver

  • Hammer

  • Punch

  • Fuel pump assembly