Fuel Pump Replacement Main

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



6. Remove the fuel pump sender assembly from the fuel tank..

•	Do Not damage the rubber insulator or the strainer.

•	Inspect the fuel pump attaching hose for signs of deterioration.

•	Inspect the rubber sound insulation at the bottom of the pump.

•	Inspect the strainer.

•	If fuel pump is bad replace the modular fuel sender assembly unit.

1. Install the fuel sender assembly into the fuel tank. Insert a new O-ring seal.
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 for the 4DR Utility.

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

5.1.	Turn the ignition ON for 2 seconds.

5.2.	Turn OFF the ignition for 10 seconds.

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

5.4.	Check for fuel leaks.

Fuel Pump Replacement Balance

Caution: Replace the O-ring seals exposed during component service in order to reduce the risk of fire and personal injury that may result from a fuel leak.

1. Disconnect the negative battery cable.
2. Loosen the filler cap(s) to relieve fuel tank pressure.



3. Disconnect the electrical connector.



4. Clean both fuel pipe connections and surrounding areas at the fuel pump before disconnecting to avoid possible contamination of the fuel system.
5. Disconnect both fuel pipes from the pump.



6. Slide the pump out of the bracket.

1. Install the new fuel pipe O-rings.



2. Position the new pump in the pump bracket.



3. Connect the fuel feed pipe and suction pipe to the fuel pump.

Tighten

•	Use a backup wrench to prevent the pump from turning.

•	Tighten the fittings to 30 N·m (22 lb ft).




4. Connect the electrical connector.
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.