Replacing Fuel Pump In 09 Suburban: Step-By-Step Guide

Changing the fuel pump on your 2009 Chevrolet Suburban is a complex process that requires specific tools and safety precautions. Before starting, ensure you have the necessary equipment and work in a well-ventilated area, as gasoline is extremely flammable and carcinogenic. Disconnect the negative battery cable and relieve the fuel system pressure. Next, raise and support the vehicle, and remove the fuel tank by disconnecting the filler neck, EVAP line, and fuel supply line. Loosen the fuel tank strap bolts and carefully lower the tank to access the fuel pump and sending unit. Disconnect the electrical connectors and fuel lines from the fuel pump, and use a suitable tool to remove the lock ring. Finally, install the new fuel pump, ensuring the correct alignment, and reverse the previous steps to reassemble the vehicle.

Disconnect the negative battery cable

Disconnecting the negative battery cable is one of the first steps to take when changing a fuel pump on a 2009 Chevrolet Suburban. Here is a detailed, step-by-step guide on how to do this:

Step 1:

Locate the negative battery terminal. This will be clearly marked, usually with a "-" symbol, and often black or dark in colour. It is typically on the left side of the battery when facing the front of the vehicle.

Step 2:

Loosen the nut or bolt that secures the negative battery cable to the terminal. You can do this with a 10mm socket and ratchet. If there is a protective cover over the nut or bolt, you may need to remove this first. Be careful not to drop the nut or bolt as you loosen it; you can place your free hand underneath to catch it if it falls.

Step 3:

Once the nut or bolt is loosened, you can carefully detach the cable from the terminal. The cable may be stiff or stuck in place, so gently wiggle it back and forth to release it. You can also try twisting the cable slightly as you pull it away from the terminal. Place the cable to one side, ensuring it does not touch any metal parts of the vehicle.

Step 4:

Check that the cable is fully disconnected by gently tugging on it. Be careful not to let it snap back into place. At this point, the battery is disconnected, and you can continue with the next steps of changing the fuel pump.

Step 5:

When you have finished working on the vehicle, you will need to reconnect the negative battery cable. Simply hold the cable in place and tighten the nut or bolt with your 10mm socket and ratchet. Ensure the connection is secure before moving on.

Remember to take appropriate safety precautions when working on your vehicle, including wearing protective gear such as gloves and eye protection.

Drain the tank

To drain the tank of your 2009 Chevrolet Suburban, first disconnect the negative battery cable. Next, raise the rear of your vehicle and support it with jack stands. Remove the clamp on the filler neck and the vent tube hose. If your vehicle is equipped with a gauge hose attached to the frame, remove this.

Now, carefully remove the support straps and insulators while supporting the tank. If your vehicle has a fuel tank shield, remove this too. Lower the tank until the gauge wiring, electrical connections, and all hoses can be removed.

It is important to note that you should always relieve the fuel pressure within the system before beginning any work on any fuel component. Failure to do so may result in fire and/or serious injury.

Remove the support straps and insulators

To remove the support straps and insulators from your 2009 GMC Suburban, you will first need to disconnect the battery negative cable. Next, drain the fuel from the tank—the more you can remove, the better. Then, raise and safely support the vehicle, ensuring it is high enough for you to work under it.

Loosen the fuel neck hose at the fuel neck and disconnect the filler neck from the tank. Support the tank and remove the tank support straps and insulator strips. Remove the frame-mounted bracket, lower the fuel tank shield, and then lower the fuel tank enough to access the fuel and electrical connections. Disconnect the fuel feed and vapor hoses, and then disconnect the electrical connectors.

Now, you can remove the fuel sender assembly and seal ring.

Remove the fuel tank

To remove the fuel tank from a 1994 Chevy Suburban, first remove the negative battery cable. Next, remove the two pipes that fill the tank. If the tank has a heat shield, you may need to remove the drive shaft to lower it. Put a support under the tank and loosen the straps that are holding it up. Slowly lower the tank and remove the two connectors on top. Then, remove the fuel lines and evap lines off the pump.

For a 1989 3/4 ton Suburban, you will need to remove the skid plate using an impact gun or air ratchet. You will also need to release the rubber hose from the tank inlet at the filler neck and stuff a rag in to prevent debris from entering. Remove the ground wire from the fuel pump attached to the frame rail. Use a floor jack and a piece of plywood to lower the tank slowly and remove the support strap bolts.

For a 1998 Suburban, you will need to remove the filler pipe. There may be another strap under the cover. Use a jack to support the weight of the tank and try to pry, wiggle, or hit it gently to dislodge it.

Install the new fuel pump assembly

Now that you've safely removed the old fuel pump, it's time to install the new fuel pump assembly. This process will involve reconnecting various hoses and components, so ensure you have your tools ready and follow these steps carefully.

Firstly, you'll want to clean the area where the new seal will be placed for the new fuel pump assembly. Use compressed air and a blow gun to remove any dirt, rocks, or debris. You can also use a screwdriver to loosen up any stubborn particles, but be careful not to stab the fuel tank.

Next, you'll need to transfer the retainer from the old fuel pump to the new one. This retainer is responsible for keeping the fuel pump locked in place. Gently squeeze the retainer to slide it off the old pump, and then attach it to the new fuel pump assembly.

Now, take the new O-ring and slide it into position on the fuel pump assembly. Make sure it's seated properly all the way around.

After that, you can slide the new fuel pump assembly into the fuel tank. Ensure that the level sensor is inserted first, and then push the assembly in, rocking it back and forth a little if necessary. Be careful not to bend or fold the fuel strainer during this process.

Once the new fuel pump assembly is in place, you can secure it using the lock ring. Start by sliding the lock ring over the fuel pump assembly and then gently tapping it into place with a brass punch and a hammer, working your way around clockwise to tighten it.

Finally, reconnect the two fuel lines to the new fuel pump assembly. Push the lines onto the connectors and make sure they are locked securely.

At this point, your new fuel pump assembly should be installed securely. You can now proceed to reattach the fuel tank and reconnect the battery before testing your new fuel pump to ensure it's working correctly.

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