Replacing Fuel Pump In '09 Silverado: Step-By-Step Guide

If your 2009 Chevrolet Silverado is exhibiting poor performance, such as engine surging or lagging, or if you notice odd stalling behaviours, it may be time to replace the fuel pump. This is a moderately complicated job that can be done at a dealership's service department or by a skilled DIYer. In this article, we will cover the steps to change the fuel pump on a 2009 Chevrolet Silverado, including relieving fuel line pressure, lifting the truck, removing the fuel tank, and installing the new fuel pump.

Relieve fuel line pressure

To relieve the fuel line pressure on a 2009 Chevrolet Silverado, follow these steps:

Firstly, open the gas cap on the side of the Silverado. Next, pull the fuel pump relay from the fuse box. Then, start the vehicle and let the engine run until it shuts down. Make sure you are working in a well-ventilated area, free from any heat sources, sparks, and open flames. Do not smoke while completing this task. After the engine has shut down, disconnect the negative battery cable. Finally, siphon the fuel out of the tank into a gas container.

These steps will relieve the pressure in the fuel system, allowing you to safely proceed with replacing the fuel pump. It is important to relieve the pressure in the fuel line to avoid any accidental spills or leaks when working on the fuel pump.

Remember to exercise extreme caution when working with fuel. Ensure the engine is cool and always wear safety goggles and other appropriate personal protective equipment.

Lift the truck

If you don't have access to a lift, you should use four jack stands and lift the entire truck rather than just the rear end for this job. Use the appropriate lifting points and place on jack stands in the manufacturer's recommended locations on level ground. If you have access to a lift, you can instead raise the rear end of the Silverado on jack stands and block the front wheels.

Use an Allen wrench to remove the screws mounting the flange for the door to the gas cap. Disconnect and remove the shield over the tank and the filler pipe's ground strap.

Remove the EVAP canister by disconnecting the hoses from the canister and removing the bracket mounting bolt. Disconnect the fuel supply and return lines; press the retaining tabs for plastic quick-connect fittings, while using a fuel line separator tool for metal collar fittings.

Support the tank by raising a transmission jack underneath it.

Remove the fuel filler neck from the tank

Removing the fuel filler neck from the tank is the third step in the process of replacing the fuel pump on a Chevrolet Silverado. This step is a little tricky because the fuel filler neck is in a difficult position to access. You will find the fuel filler neck on the driver's side of the tank and above the frame. This large-diameter hose is connected to the tank with a hose clamp. To remove it, use a stubby flat-head screwdriver to loosen the hose clamp. The fuel filler neck should then pull right off fairly easily.

Before you begin this step, make sure you are working in a well-ventilated area free of any heat sources, sparks, and open flames. Do not smoke while working around fuel sources. It is also recommended to wear safety goggles to prevent gasoline from getting into your eyes.

If you are having trouble locating the fuel filler neck, it may be covered by a gas cap door. To access it, you will need to remove the screws mounting the flange for the door using an Allen wrench. You may also need to remove the shield over the tank and the filler pipe's ground strap.

Once you have located the fuel filler neck, use a stubby flat-head screwdriver to loosen the hose clamp that connects it to the tank. The fuel filler neck should then be able to be pulled off fairly easily. Be careful not to spill any fuel during this process.

If you are unable to locate the fuel filler neck or are having difficulty removing it, you may need to seek additional assistance or refer to a repair manual for further guidance.

Disconnect the fuel tank lines

To disconnect the fuel tank lines, start by moving to the passenger side of the tank. Wear safety goggles to protect your eyes from any gasoline spillage. Begin with the vapor line, disconnecting it from the charcoal overflow tank. Next, move on to the larger supply line and disconnect it. These two lines have similar connectors that you'll need to squeeze at the base to release. With a little wiggle, they should come off easily.

There are two more lines above the vapor and supply lines that need to be disconnected as well. These will also pop right off, but they have white connector clips that must be pushed in simultaneously as you pull on the hose. Be prepared for some gasoline spillage, even though most of the pressure will have been released earlier.

Once you have disconnected all four lines, you can proceed to the next step, which is disconnecting the power lines to the fuel pump.

If you are unable to access the fuel tank lines or are uncomfortable performing this task, it is recommended to consult a professional or a service center.

Disconnect power lines to the fuel pump

To disconnect the power lines to the fuel pump of your 2009 Chevrolet Silverado, follow these steps:

First, relieve the pressure within the fuel system. Open the gas cap on the side, remove the fuel pump relay from the fuse box, then start the vehicle and let it run until it stalls. Disconnect the negative battery cable.

Next, move to the passenger side of the fuel tank. There are two quick-release electrical plugs on top of the fuel tank that power the fuel pump. Disconnect these plugs from the pump.

Now, you will need to remove the fuel tank. Raise the rear end of the Silverado on jack stands and block the front wheels. Use an Allen wrench to remove the screws mounting the flange for the door to the gas cap. Disconnect and remove the shield over the tank and the filler pipe's ground strap. Remove the EVAP canister by disconnecting the hoses from the canister and removing the bracket mounting bolt. Disconnect the fuel supply and return lines. Support the tank by raising a transmission jack underneath it, then unbolt and remove the straps and lower the tank.

Finally, unplug the electrical connectors to the fuel pump module. Disconnect the filler hose from the tank by loosening its clamps and removing the tank.

You have now successfully disconnected the power lines to the fuel pump. The next step in changing the fuel pump is to disconnect the EVAP and fuel lines from the pump module on top of the tank.

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