How to Install a Fuel Pump in Chevrolet Cars

The fuel pump on a Chevrolet car pumps the fluid from the gas tank to the engine. These fuel pumps are mounted in the gas tank and use the gasoline to cool itself. If you run the vehicle low on fuel frequently, you run a risk of overheating the pump. It's a critical component of the fuel injection system, and if it fails, there is no way for the gasoline to get from the tank to the engine--and when that happens, the engine won't be able to run as well.

Under The Hood:

• How to Install a Fuel Pump in a 1997 Chevy Suburban
• How to Install a Fuel Pump on a Chevrolet 350 Engine
• How to Install a Fuel Pump on a 2002 Chevy Duramax
• How to Install a Fuel Pump on a 2003 Chevy Suburban
• How to Install a Fuel Pump on a 2001 Chevy Malibu

 How to Install a Fuel Pump in a 1997 Chevy Suburban

Lift up the driver's side of the truck using the jack and put it onto jack stands. Crawl underneath the truck and locate the connection between the gas filler neck and the gas cap. Unscrew the hose clamps on the hoses using the flathead screwdriver and pull away the hose.

Put the wood block on the head of the jack. Lift the jack until it contacts the base of the tank. Unbolt the gas tank from the frame using the 3/8-inch ratchet, extension and sockets. Lower it with the jack slowly until you can access the top of the gas tank. Remove the hose clamps on the fuel lines using the flathead screwdriver, then unplug the fuel pump from the tank. Lower the tank all the way and then slide it out from under the frame.

Remove the locking cam mounted around the fuel pump using the brass hammer and brass drift. Lift up the old fuel pump and discard it. Set the replacement fuel pump into the tank and reinstall the locking cam using the brass hammer and drift.

Lift the tank into the frame using the jack. Reattach the electrical connection to the pump and then reinstall the fuel lines with the flathead screwdriver. Attach the pump to the frame using the 3/8-inch ratchet, extension and sockets, then reattach the fuel filler neck to the tank.

 How to Install a Fuel Pump on a Chevrolet 350 Engine

Removal of Old Fuel Pump

Disconnect the fuel lines from the existing fuel pump. The fuel pump is located on the passenger's side of the engine, just below the water pump. Two fuel lines attach to the front of the fuel pump. One fuel line slides over a metal nipple and is secured with a hose clamp. The tip other fuel line bolts into the fuel pump. Loosen the hose clamp with a flathead screwdriver. Pull the first hose off of the fuel pump. Twist the metal tip of the remaining fuel line in a counterclockwise direction until the line is loose. Pull the line away from the fuel pump.

Remove the existing fuel pump by removing the pump's two retaining bolts with a wrench. Pull the pump out of the side of the engine.

Remove any remaining gasket material from the surface of the engine where the old fuel pump was located. This surface must be clean to ensure that the new gasket will seal properly. The surface can be cleaned with either a gasket scraper or with the blade of a flathead screwdriver.

Install the New Fuel Pump

Coat one side of the new fuel pump gasket with gasket sealer. Place the coated side of the gasket against the fuel pump. Coat the opposite side of the gasket with gasket sealer.

Insert the metal arm which exits the back of the fuel pump into the side of the engine until the fuel pump rests evenly against the engine.

Insert both of the pump's retaining bolts through the pump and into the engine. Tighten each bolt with a wrench.

Insert the tip of the fuel line which bolts to the pump into the pump. Tighten the line with a wrench.

Slide the remaining fuel line over the metal nipple on the fuel pump. Tighten the hose clamp with a flathead screwdriver.

 How to Install a Fuel Pump on a 2002 Chevy Duramax

Disconnect the negative battery cable on the Chevy using a wrench to loosen the nut on the terminal. This is important because there is a risk of electrical shock. Loosen the gas cap to relieve the fuel system pressure.

Unplug the wiring harness from the fuel pump. The fuel pump is under the truck on the driver side, just behind where the seat would be. Clean the entry and outlet fittings on the fuel pump using a rag. Place a drain pan under the pump and loosen the fittings using a wrench. Slide the fuel pump from the mounting bracket.

Insert the new fuel pump into the mounting bracket, making sure to place it properly according to the inlet and outlets. Connect the fuel lines and tighten the fittings with a wrench.

Plug the wiring harness into the fuel pump. Connect the negative battery cable and tighten the nut with the wrench. Place the gas cap back on the filler pipe. Start the truck to test the installation.

 How to Install a Fuel Pump on a 2003 Chevy Suburban

Open the hood of the 2003 Suburban. Disconnect the negative battery cable. Remove the fuse and relay from the fuse and relay box that operate on the fuse pump circuit.

Open the driver's side gas filler cap. Put the nozzle of the siphon into the gas filler pipe. Insert the other end of the siphon to the gas can. Pump out the gas from the Suburban's fuel tank into the gas can. This action relieves the weight of the fuel from the tank and ensures that fuel doesn't spill on you when you move the tank and the pump.

Chock the front wheels. Raise the rear of Suburban with your floor jack. Place two jack stands under the frame, and lower the Suburban on the stands.

Put on your latex gloves. Loosen the metal collar ring of the filler pipe hose on the side of the gas tank. Pull the hose off of the tank. Repeat this process for the vent hose on the side of the tank.

Position the floor jack below the gas tank. Remove the bolt holding the forward fuel tank strap. Push the strap out of the way. Pry the fuel tank away from the frame rail to have the forward end of it drop onto the floor jack.

Disconnect the now-visible hoses and lines from the fuel pump. Depress the tabs of the wiring harness. Twist off the fuel return and EVAP hoses. Remove the final strap. Pull the fuel tank on the floor jack into a position where you can see it fully.

Clean the area around the fuel pump on the tank with an acetone cleaning agent. This prevents contaminants from getting into the fuel tank.

Remove the locking ring from around the fuel pump. Hit each tab on the locking ring with your hammer and brass punch in a counterclockwise direction. Using the brass punch will ensure that you don't create sparks. This loosens the tabs from the slots of the fuel tank.

Pull out the fuel pump and o-ring gasket.

Lubricate the new o-ring gasket with a smear of motor oil. Set the gasket below the head of the fuel pump. Slide the fuel pump into the fuel tank. Orient the stems of the fuel pump between the hatch mark grooves on the surface of the fuel tank. Lock the fuel pump into place by remounting the locking ring with the hammer and brass punch.

Remount the fuel tank and reconnect the hoses and electrical connection.

Reconnect the battery and the fuel pump fuse and relay.

Refill the gas in the fuel tank.

Turn the ignition to "On." Wait 10 seconds. Turn the ignition to "Lock." Repeat this process at least three more times. This action turns on the fuel pump and sends fuel through the fuel system. Check below the Suburban for any fuel leaks. Tighten any fittings that are leaking. Remove the car jack and jack stands.

 How to Install a Fuel Pump on a 2001 Chevy Malibu

Raise the rear of the vehicle and place jack stands under the pinch welds on the lower body rocker panel. There are reinforced areas here that are designed to support the weight of the vehicle. Lower the car onto the jack stands and remove the floor jack. Unscrew the fuel filler cap to help relieve pressure that builds up in the tank due to fuel evaporation.

Disconnect the plastic fuel lines leading from the tank to the front of the vehicle by pushing in on the line while depressing the quick disconnect fittings. Unplug the vapor return line and the fuel pump's electrical connector. Remove the fuel filler neck hose by loosening the hose clamps with a screwdriver and prying the hose loose with a large pry bar.

Remove the two rubber exhaust system hangers located near the rear of the exhaust. This will allow the exhaust to move when removing the fuel tank. Remove the metal heat shield from the bottom of the car.

Place the floor jack under the fuel tank, with a large flat piece of wood between the jack and the tank, and lift the tank slightly. This will take the weight of the tank off the straps attaching the tank to the undercarriage of the car. Remove the straps holding the tank to the body of the car, and lower the fuel tank. Slide the fuel tank past the exhaust system, and out from underneath the car.

Remove the fuel pump assembly by turning the spring-loaded retaining ring with the hammer and chisel. Lift the whole assembly out of the fuel tank by lifting the assembly up and then rotating it over to clear the level sensor arm. Unsnap the top, and separate the plastic housing to gain access to the fuel pump. Remove the fuel pump electrical connector, and remove the pump from the assembly by pushing the pump up and over until it clears the assembly.

Install the new pump into the assembly using the new rubber coupler and the new vibration cushion supplied with the pump. Plug the electrical connector into the new pump, and snap the two halves of the plastic housing back together. Install the assembly back into the tank, and rotate the spring-loaded retainer using the hammer and chisel.

Reposition the tank under the car, and lift the tank into place with the floor jack. Install and tighten the retaining straps, heat shield and filler neck hose clamps. Reinstall the exhaust system hangers. Plug the electrical connector back into the assembly. Reconnect the fuel lines and vapor line.

Lower the vehicle off the jack stands and prime the fuel system by cycling the ignition key from off to run a few times. Start the engine and check for leaks