How to Replace the Fuel Pump on a 1996 Chevy Truckby Eli Laurens; Updated November 07, 2017
Items you will need
The fuel pump on a 1996 Chevrolet truck is mounted at the top of the fuel tank, wired and routed from several connectors at its front. The fuel pump can wear out and require replacement, but removal of the fuel tank is required. The procedure is not complex, but proper preparation can reduce the time and effort necessary. The average backyard mechanic can replace the fuel pump in a 1996 Chevy tuck in about two hours.
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.
If pumps are failing continuously, check the emissions system for proper operation.
Use caution when working around electricity and gasoline.