Fuel Pump Removal and Instalation.
Fuel Injected vechiles have the fuel pump in the fuel tank. In order to replace pump tank must be removed. Depending on how much gas is in the tank you might want to sphion gas out first. Use a long hose, insert into tank via fuel inlet. (not advised but this is how I do it) **** on the hose till gas starts coming out. Let drain into gas can so you can reuse after pump is replaced. Most vechiles have two tubes running from fill neck to the tank. There will be two hoses running between them with usually a hose clamp on it. If there isn't a reusable clamp break the clamp other wise undo clamps. There is also another two if not three lines running from the top of the tank to engine bay. The two that is there is for sure is, one is fuel line, the other fuel return line. They are connected on top of the tank. Sometimes there is another connection within reach without lowering tank but most times this isn't the case. If you can reach, dissconnect now, otherwise dissconnect when you have enough room to access these hoses. There is also a wire connection. Again usually on top of the tank it can be dissconnected but sometimes it can be reached before tank is lowered. Again, remove when able too. Then you can lower the tank. Put a floor jack under the tank and then you can remove the straps that hold the tank in place. Now slowly lower the jack and make sure the lines are free. Lines mean fuel lines, inlet, and wires. Once tank is out there are usually three ways the fuel pump is held in. One is with a C-clamp. C-clamp tools are prefeered but can use two punches. Second is with a metal ring. You need a hammer and a small chisel. There will be three or four tabs on this, you slightly tap each tab counter clock wise utnil ring is off. Third is a rare option. It's just a plastic screw ring. Again loosen counter clock wise. Once the ring/clamp is removed you can remove the pickup with also holds the pump and fuel level sensor. You may have to twist/turn pickup tube in awakard postions to remove from the tank. Then follow the directions that came with the new fuel pump to replace pump. Some are quick easy replacements others you might need to cut/splice wires in order to replace with new pump. When you remove the pickup tube there should be a big black O-ring that helps seal up the tank. New one should come with the pump. If not use old one if it's not damaged. LUBE O-RING UP BEFORE REINSTALLING. This will make it easier on you and reduce the chance of damaging the ring while reinstalling. If you damage the oring and don't notice it, GAS WILL LEAK THE FIRST TIME TANK IS FILLED UP. Replace the tank just as you took out. Now if you're working with a plastic tank, DO NOT USE JACK TO LIFT TANK INTO PLACE. You can bend the pickup tube so that it only get gas from the top half of the tank. Ask a buddy to help you instead. If this is on a Camaro, Firebird, or other sports cars, exhaust has to be removed if not also rear axle disconnected to remove tank. Pickup trucks the bed can be lifted off instead if wanted. Remove the 6-8 bolts holding bed on. Disconnect fill and vent tubes. Disconnect tail light connections at frame. Remove tail gate and usually with two guys a bed can be removed for easy work on the fuel pump. Any way you replace the fuel pump it a pain but can be completed if you take your time and pay attention.
on Feb 21, 2010 | Chevrolet C1500 Cars & Trucks