Question about 2002 Chevrolet Suburban 2500

1 Answer

Intermittent stalling like it is starved for fuel. WHen I open the gastank cap most of the time it will start right up. If not, then banging on the fuel tank to free up the fuel pump works. It is at the dealership now, they had a number of codes come up and suspect it is the transfer pump between the two gas tanks, a $1300 repair. I still suspect it is a vacuum in the tank and gas lines and concerned that this expensive repair may not solve the problem. Any ideas or suggestins?

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  • denisokeefe Sep 02, 2010

    the pump they want to replace is the transfer pump, not the fuel pump in the tank. what controls the vacuum level or fuel pressure ( other than the fuel pump)?

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  • Chevrolet Master
  • 6,826 Answers

If you have to bang on the tank to get the pump going, I'm thinking that it is a fuel pump. If the expensive repair doesn't prove to solve the problem, I would think that there would be recourse for the less expensive repair (the vacuum in the tank and gas lines).

Actually, the fuel pump is the likely culprit, in my opinion based on what was written about the problem, unfortunately.

Good luck on the repair.

Posted on Sep 02, 2010

  • Duane Wong
    Duane Wong Sep 02, 2010

    You're right, the transfer pump is different than the fuel pump.
    The following describes the fuel pressure regulator on the different engine sizes of the Suburban.

    I'm not sure why you have a vacuuum in the tank vs. actual pressure, but I suspect the transfer pump between the two gas tanks is the culprit since codes come up for that.



    I might consider asking them to guarantee that their work will solve the problem before signing on the dotted line.

    Removal & Installation
    4.8L, 5.3L & 6.0L Engine
    To Remove:

    CAUTION
    Three styles of fuel pressure regulators and fuel rails will be used in this model year. Each regulator has a different "footprint" that consequently changes the size of the receiving port in the fuel rail. The regulator retaining clips are specific to each rail-regulator design and cannot be interchanged.












    1. Remove the engine sight shield.
    2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure.
    3. Clean the fuel pressure regulator retainer and the surrounding area.
    4. Remove or disconnect the following:

      • Fuel pressure regulator vacuum line.
      • Fuel pressure regulator retainer.
      • Fuel pressure regulator.

    5. Remove the following parts from the fuel rail:

      • Backup ring (10)
      • Regulator Seal O-ring (11)
      • Regulator filter (12)
      • Regulator seal O-ring (13)

    To Install:












    1. Make sure the NEW fuel pressure regulator retainer is the right one.
    2. The tabs (1) are used on the straight vacuum port retainer (2), and the E85-straight vacuum port retainer (3).
    3. The angle vacuum port retainer (4) has no tabs.










    4. Install the following parts onto the fuel pressure regulator (9).

      • Backup ring (10)
      • Regulator seal O-ring (11)
      • Regulator filter (12)
      • Regulator seal O-ring (13)

    5. Lubricate the fuel pressure regulator O-rings with clean oil.
    6. Install the fuel pressure regulator and retainer.
      CAUTION
      Whenever the fuel pressure regulator is removed from the fuel rail NEW O-rings and a NEW retaining clip should be used on reinstallation.

    7. Connect the vacuum line.
    8. Tighten the fuel filler cap.
    9. Use the following to inspect for leaks:

      • Turn ON the ignition, with the engine OFF, for 2 seconds.
      • Turn OFF the ignition for 10 seconds.
      • Turn ON the ignition, with the engine OFF.
      • Install the engine sight shield.

    8.1L Engine
    To Remove:






    Fuel pressure regulator vacuum line





    1. Before servicing the vehicle refer to the precautions at the beginning of thjs section
    2. Remove the fuel injector sight shield as needed
    3. Relieve fuel system pressure (See: Fuel Pressure Relieving)
    4. Disconnect the fuel pressure regulator vacuum line (A)





      8.1L Fuel pressure regulator retainers




    5. Clean any dirt from the fuel pressure regulator retainer and the surrounding area
    6. Remove the fuel pressure regulator retainer (I)
    7. Remove the fuel pressure regulator (H) from the fuel pressure regulator housing

    To Install:






    8.1L Fuel pressure regulator retainers





    1. Install or connect the following:

      • Backup ring (J) on the fuel pressure regulator (H)
      • New large O-Ring (K) on the fuel pressure regulator
      • Regulator filter (L) on the fuel pressure regulator
      • New small O-Ring (M) on the fuel pressure regulator

    2. Lubricate the fuel pressure regulator large O-Ring and the small O-Ring with clean engine oil
    3. Push the fuel pressure regulator onto the regulator housing on the fuel rail
    4. Install a new fuel pressure regulator retainer (I)
    5. Install or connect the following:

      • Fuel pressure regulator vacuum line
      • Negative battery cable

    6. Tighten the fuel filler cap
    7. Inspect for leaks using the following procedure:

      • Turn on the ignition with the engine off for two seconds
      • Turn off the ignition for 10 seconds
      • Turn on the ignition with the engine off
      • Inspect for fuel leaks

    8. Install the fuel injector sight shield
    9. Road test the vehicle to check performance


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