Replacing Fuel Pump In 2002 Blazer: A Step-By-Step Guide From The Top

Replacing the fuel pump in a 2002 Chevrolet Blazer can be a moderately complicated job. The fuel pump is located inside the fuel tank and can be accessed through an access panel in the passenger compartment or by removing the tank from the vehicle. Before attempting to replace the fuel pump, it is important to empty the tank as much as possible and jack up the truck to loosen the straps holding the tank in place. It may be necessary to replace certain hangers or hardware, and caution should be exercised to avoid cutting a hole in the floor or drilling/cutting into the tank. Once the tank is dropped, the ring holding the sending unit in the top of the tank can be turned to access the fuel pump for replacement.

Jack up the truck and loosen the straps holding the tank

Jacking up your truck is a crucial step in accessing and repairing the underside of your vehicle. This process will likely involve using a jack and jack stands to lift the truck and support it securely. Here is a step-by-step guide to help you through the process:

• Park your truck on a flat, level surface, such as a paved driveway or a smooth patch of ground. Ensure you engage the parking brake fully.
• Place wheel chocks—wedge-shaped blocks—behind the drive wheels to prevent accidental rolling.
• Identify the jacking points on your truck's frame. These are reinforced areas designed to support the weight of the vehicle when lifted. Consult your owner's manual if you're unsure about the exact locations.
• Position a jack beneath the truck, aligning it with one of the designated jacking points. Ensure the jack is on stable ground.
• Begin cranking the jack to lift the truck slowly. Continue until the truck's wheels are off the ground, and the chassis is at your desired height.
• Place jack stands under additional jacking points to support the truck's weight. These will ensure stability and safety while you work.
• Lower the jack until the vehicle's weight rests on the jack stands. Do not rely solely on the jack to support the vehicle.

With the truck securely elevated, you can now proceed to loosen the straps holding the fuel tank. Here are the steps to guide you through this process:

• Locate the fuel tank straps. They are usually made of metal and are bolted to the vehicle's frame or fuel tank brackets.
• Using the appropriate tools, loosen the bolts that secure the fuel tank straps. Be cautious and avoid completely removing the bolts or detaching the straps until you're ready to lower the fuel tank.
• Once the bolts are loosened, adjust the straps as needed to access the fuel pump. This may involve moving or repositioning the straps to create sufficient workspace.
• If you need to remove the fuel tank, support it with a jack or a fuel tank hoist before completely detaching the straps. This will prevent the tank from falling and causing injury or damage.
• With the straps loosened and adjusted, you can now access the fuel pump for inspection, repair, or replacement. Remember to follow all safety precautions when working with fuel system components.

Remember, always exercise extreme caution when working under a vehicle. Ensure that the truck is securely supported on jack stands and that the parking brake is engaged. Never work alone, and always have a spotter nearby in case of an emergency.

Undo all electrical and fuel connections

Disconnecting auto electrical connectors is an essential skill for maintaining your car's electrical system. Auto electrical connectors are designed to stay connected under high speeds and vibrations from the engine, so it is important to understand the basic design of their locking system.

• Identify the connection you want to disconnect. Pull the connection up and away from the other wires around it. If necessary, use a pair of small scissors to cut the small plastic wire ties that may be holding the wires together. You will need enough space to easily work on the connection with both hands.
• Examine the connection closely. There will be a "female" end and a "male" end. The male end inserts into the female end. Identify the female end and look for a tab on the top or sides of the connection.
• If a tab is present, hold the female end in one hand and use your other hand to push down or in on the locking tab to release it. Be careful not to use excessive force, as some plastics may become brittle with age and break easily. If there is no tab, simply hold the female end firmly in one hand.
• Pull the male end of the connector away from the female receiver. Make sure you are gripping the plastic connector and not the wires. If the connector is heavily corroded, you may need to apply a penetrating oil or treatment and wait a few minutes before pulling the connection apart.
• For fuel connections, you will need to access the fuel pump, which is located inside the fuel tank. You can access the fuel pump through an access panel in the passenger compartment or by removing the fuel tank from the vehicle. This is a moderately complicated job, and it may be best to have it performed by a professional mechanic or dealership service department.

Remember to always exercise caution when working on your vehicle's electrical and fuel systems, and refer to a professional mechanic if you are unsure about any steps.

Remove the fuel tank

To remove the fuel tank from a 2002 Chevrolet Blazer, you will need to perform the following steps:

Firstly, loosen the filler neck hose clamp that is attached to the fuel tank. You can then disconnect the fuel tank filler neck from the fuel tank itself. Next, you will need to support the fuel tank with a piece of wood on a jack. Remove the fuel tank shield; this is attached with four bolts. Once the shield is removed, you can then remove the tank straps, which are secured with two bolts.

Now that the tank is almost free, you will need to slowly lower it, being careful not to let any hoses get caught. Once the tank is lowered, you can disconnect the fuel and vapor hoses, as well as the electrical connections at the sender. It is important to note that this is a moderately complicated job and is best performed by a professional mechanic at a dealership's service department.

Turn the ring holding the sending unit in the top of the tank

To turn the ring holding the sending unit in the top of the tank, you will need to first remove the fuel tank from the vehicle. This can be done by following these steps:

• Remove the fuel from the gas tank.
• Loosen clamps at the fuel filler tube and rubber tubing.
• Loosen clamps from the breather tube coming out of the top of the tank.
• Position a floor jack under the tank to support it and place a thin wooden board as a cushion.
• Remove the bolts holding the tank straps and then remove the straps themselves.
• Lower the jack while also working on loosening the filler tube and breather tube hoses from the filler inlet.
• Lower the driver's side of the tank, using the filler tube to hold up the passenger's side.
• Spray penetrating lubricant on the fuel line connectors and allow it to sit.
• Disconnect the electrical connector for the fuel pump and the ground connector at the frame.
• With one hand, work your way to the fuel line connectors and loosen them with a wrench. You will need both a line/tubing wrench and a regular wrench.
• Ensure all lines, hoses, and connectors are disconnected before lowering the tank completely.

Once the tank is out, you can remove the fuel pump by tapping the ring with a screwdriver and working it around until it is loose. There is also a special tool designed for this purpose.

When you are ready to install the new fuel pump, simply reverse the process. Position the tank under the rear of the vehicle and use a floor jack to lift it into place, reconnecting all the lines, hoses, and connectors. Finally, tap the locking ring back into place to secure the fuel pump assembly.

Replace the fuel pump

Step 1: Prepare the Vehicle

First, empty the tank as much as possible. Jack up the truck and loosen the straps holding the tank in place. Disconnect all electrical and fuel connections.

Step 2: Remove the Fuel Tank

You may need an extra pair of hands for this step. Undo the ring holding the sending unit in the top of the tank (the fuel pump is attached to the sending unit). Now carefully lower the tank.

Step 3: Remove the Old Fuel Pump

With the tank out, you can now access the fuel pump. Turn the ring holding the sending unit to remove the fuel pump.

Step 4: Install the New Fuel Pump

Install the new fuel pump onto the sending unit, ensuring it is securely attached. Carefully lift the tank back into place and reconnect all electrical and fuel connections. Reattach the straps to secure the tank.

Step 5: Refuel and Test

Refuel the vehicle and start the engine. Check for any leaks around the fuel tank and lines. If no leaks are detected, turn off the engine and refill the tank.

Note: Some sources suggest alternative methods for accessing the fuel pump, such as cutting a hole in the floor or lowering the tank slightly, but these are generally not recommended and may cause unnecessary damage. It is best to follow the steps outlined above to safely and effectively replace the fuel pump.

Frequently asked questions