Replacing Fuel Pump In '91 Chevy 1500: Step-By-Step Guide

If you're looking to replace the fuel pump in your 1991 Chevy 1500, there are a few steps you'll need to follow. Firstly, disconnect the negative battery cable and relieve the fuel system pressure. Next, raise the vehicle and support it with jack stands. Drain the fuel system and remove the fuel tank. Remove the fuel sender assembly by turning it counterclockwise, and then remove the assembly from the tank. Pull the pump up and out of the attaching hose and bottom support, being careful not to damage the rubber insulator or strainer. After inspecting the hose, rubber sound insulation, and strainer for any signs of damage or blockage, you can install the new fuel pump assembly, being careful not to bend or fold the fuel strainer. Reinstall the fuel sender and fuel tank, reconnect the negative battery cable, and turn the ignition switch on and off to check for leaks.

Disconnect the negative battery cable

Disconnecting the negative battery cable is the first step in replacing the fuel pump in a 1991 Chevy 1500. This is a crucial safety measure as it ensures that the vehicle's electrical system is inactive during the repair process. Here are some detailed instructions on how to do this:

First, locate the negative battery cable. It is typically black and connected to the negative terminal of the battery, which is usually marked with a "-" symbol. Before proceeding, ensure that you are wearing protective gear, such as gloves and eye protection, to safeguard against any potential electrical hazards.

Once you have located the negative battery cable, proceed to loosen the nut or bolt that secures the cable to the battery terminal using the appropriate tool, such as a wrench or socket. It is important not to allow the cable to fall back into place, so you may want to use a piece of tape or a cable tie to secure it out of the way.

Now, carefully remove the cable from the battery terminal. Be cautious not to let the cable touch any metal parts of the vehicle, as this could potentially cause a short circuit. Place the cable in a safe location away from the battery and any metal components.

With the negative battery cable disconnected, you can be assured that the electrical system is inactive, and you can proceed with the next steps of the fuel pump replacement process, which include relieving the fuel system pressure, raising the vehicle, and draining the fuel tank.

It is important to note that working on a vehicle's fuel system can be dangerous due to the flammable nature of gasoline. Always take the necessary precautions, such as working in a well-ventilated area and avoiding open flames or sparks. Refer to a trusted repair manual or seek the assistance of a qualified mechanic if you are unsure about any part of the process.

Relieve the fuel system pressure

To relieve the fuel system pressure of a 1991 Chevy 1500, follow these steps:

Firstly, ensure the engine is turned off. Then, refer to the fuel system relief procedure in the service manual. This will guide you through the process of relieving the pressure. It is important to note that you should not start this process before disconnecting the negative battery cable.

After relieving the pressure, you can continue with the rest of the procedure to replace the fuel pump. This includes raising the vehicle with jack stands, draining the fuel system, and removing the fuel tank.

Relieving the fuel system pressure is a crucial step in ensuring your safety when working on the fuel pump of your 1991 Chevy 1500. Always refer to the service manual for detailed instructions.

Drain the fuel system

To drain the fuel system of a 1991 Chevy 1500, follow these steps:

First, relieve the fuel system pressure. This is an important safety precaution to prevent injury and damage. Refer to your vehicle's fuel system relief procedure for specific instructions on how to do this.

Next, disconnect the negative battery cable. This will prevent any accidental electrical discharge during the process.

Now, you need to raise the vehicle and support it safely with jack stands. This will give you access to the fuel tank and pump. Place the jack stands on level ground and ensure they are securely engaged to support the weight of the vehicle.

Once the vehicle is securely raised, locate the fuel tank and drain the fuel system. This step will involve removing the fuel tank. Refer to your vehicle's fuel tank removal procedure for detailed instructions on how to do this.

After draining the fuel system, you can proceed with the rest of the fuel pump replacement procedure. Remember to exercise caution and refer to the appropriate procedures and guidelines for your vehicle to ensure a safe and effective repair process.

Remove the fuel tank

To remove the fuel tank from a 1991 Chevy 1500, start by disconnecting the negative battery cable. Next, relieve the fuel system pressure. Then, raise the vehicle and support it with jack stands. Drain the fuel system and remove the fuel tank.

Now, you can remove the fuel sender assembly. To do this, turn it counterclockwise using tool J-39765 or its equivalent, and then remove the assembly from the tank. Pull the pump up and out of the attaching hose, being careful not to damage the rubber insulator or strainer.

Once the pump is clear of the bottom support, you can pull it out of the rubber connector. Inspect the fuel pump attaching hose and the rubber sound insulation for any signs of deterioration. Also, check the strainer for any blockages or damage.

Now that the fuel pump has been removed from the tank, you can proceed to install the new fuel pump assembly.

Remove the fuel sender assembly

To remove the fuel sender assembly of a 1991 Chevy 1500, follow these steps:

Firstly, relieve the fuel system pressure. Refer to the fuel system relief procedure in your manual. Next, disconnect the negative battery cable. Then, raise the vehicle and support it safely with jack stands. Drain the fuel system and remove the fuel tank, referring to the manual for the fuel tank removal procedure.

Now, you can remove the fuel sender assembly. Turn it counterclockwise using tool J-39765 or its equivalent, and then remove the assembly from the tank. Pull the pump up into the attaching hose while simultaneously pulling it outward from the bottom support, being careful not to damage the rubber insulator or the strainer.

Once the fuel sender assembly is removed, you can inspect the fuel pump attaching hose, rubber sound insulation, and strainer for any signs of damage or blockage.

Frequently asked questions