Fuel Pump Replacement Main

Tools Required

J 39765 Fuel Sender Locknut Wrench.

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. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure
3. Drain the fuel tank. Refer to Fuel Tank Draining Procedure .
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 (4 Door Utility) for the 4DR Utility.




5. Remove the fuel sender assembly by turning the cam lock counterclockwise using J 39765 .

1. Note the position of the fuel pump strainer on the fuel pump.
2. Support the pump with one hand and grasp the strainer with the other hand.
3. Rotate the strainer in one direction and pull off the pump. Discard the strainer after inspection.
4. Inspect the fuel pump strainer. Replace the strainer if it has contaminates and clean the fuel tank. Refer to Fuel System Cleaning .
5. Inspect the fuel pump inlet for dirt and debris. If found, replace the fuel sender assembly.

Notice: Do not fold or twist the strainer when installing the sending unit. This action restricts fuel flow.

1. Support the pump with one hand and position the new pump strainer on pump in the same position as noted during disassembly.
2. Push on the outer edge of the ferrule until fully seated.

1. Install a new seal, sending assembly and lock ring. Make sure the lock ring alignment holes fit over the tabs on the tank.
2. Install the cam lock assembly. Turn the cam lock clockwise to lock it.
3. 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 (4 Door Utility) for the 4DR Utility.

4. Add fuel removed from the tank.
5. Connect the negative battery cable.
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.