Fuel Pump Replacement Main

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Remove the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure
3. Raise the vehicle.
4. Remove the fuel tank.

•	Refer to Fuel Tank Replacement (Suburban) for the Suburban.

•	Refer to Fuel Tank Replacement (Tahoe/Yukon) for the Yukon/Tahoe.

•	Refer to Fuel Tank Replacement (Pick-up - Side Tank) for the Pick-up.

•	Refer to Fuel Tank Replacement (Extended Cab - Side Tank) for the Extended Cab.

•	Refer to Fuel Tank Replacement (Cab and Chassis - Side Tank) for the Cab and Chassis with a side tank.

•	Refer to Fuel Tank Replacement (Cab and Chassis - Rear Tank) for the Cab and Chassis with a rear tank only.

•	Refer to Fuel Tank Replacement for the 4DR Utility.




5. Reomove the fuel sender unit assembly by turning the cam lock counterclockwise using tool J 39765 .
6. Disconnect the fuel pump from the sender assembly.

•	Pull the fuel pump up into the attaching hose while pulling outward from the bottom support.

•	Do Not damage the rubber insulator or the strainer.

7. Inspect the fuel pump attaching hose for signs of deterioration.
8. Inspect the rubber sound insulation at the bottom of the pump.
9. Inspect the strainer.

1. Connect the fuel pump assembly into the attaching hose.



2. Install the fuel sender assembly into the fuel tank. Insert a new O-ring seal.
3. Install the cam lock assembly. Turn the cam lock clockwise to lock it.
4. Install the fuel tank.

•	Refer to Fuel Tank Replacement (Suburban) for the Suburban.

•	Refer to Fuel Tank Replacement (Tahoe/Yukon) for the Yukon/Tahoe.

•	Refer to Fuel Tank Replacement (Pick-up - Side Tank) for the Pick-up.

•	Refer to Fuel Tank Replacement (Extended Cab - Side Tank) for the Extended Cab.

•	Refer to Fuel Tank Replacement (Cab and Chassis - Side Tank) for the Cab and Chassis with a side tank.

•	Refer to Fuel Tank Replacement (Cab and Chassis - Rear Tank) for the Cab and Chassis with a rear tank only.

•	Refer to Fuel Tank Replacement for the 4DR Utility.

5. Add fuel removed from the tank.
6. Check for fuel leaks.

6.1.	Turn the ignition ON for 2 seconds.

6.2.	Turn OFF the ignition for 10 seconds.

6.3.	Again, turn the ignition switch to the ON position.

6.4.	Check for fuel leaks.