Changing Fuel Pump In Chevy Silverado: Diy Guide

If you need to replace the fuel pump in your 2002 Chevy Silverado, one option is to use the bed tilt method. This method does not require draining the gas tank or removing the entire bed from the truck. Instead, you can tilt the bed to access the fuel pump, which is located on top of the tank. This method can be completed by one person and can save time and effort compared to other fuel pump replacement methods.

Removing the tailgate and cap

Before starting, ensure you have the necessary tools, such as a ratchet, extension, breaker bar, and socket, as well as personal protective equipment like gloves and eye protection. It is also recommended to have cardboard or a similar material to place between the bed and cab to protect the finish.

First, locate the bolts attaching the tailgate. These bolts will need to be removed. Depending on your model, there may be three or four bolts on each side, with the ones towards the cab being more challenging to access. An extension for your ratchet will be helpful in reaching these bolts. If the bolts are rusted or difficult to remove, a breaker bar and an additional person to help hold the socket in place or turn the breaker bar can be beneficial.

Once the bolts are removed, you can proceed to remove the tailgate. Place a jack under the side with the fuel pump and use wooden blocks, such as 2x4s, to securely support the bed. Ensure the blocks are sturdy and properly positioned to bear the weight of the bed.

Now, let's address the cap. In most cases, removing the cap is not necessary. However, if your cap is very close to the cab, there may be a risk of it hitting when you tilt the bed. Assess your specific situation and decide accordingly. If you decide to leave the cap on, ensure it is securely attached and won't obstruct the bed tilt process.

After addressing the tailgate and cap, you can continue with the next steps of the fuel pump replacement process, such as disconnecting electrical connections and fuel lines. Remember to work safely and follow established procedures for fuel pump replacement.

By following these steps, you can effectively remove the tailgate and address the cap on your 2002 Chevy Silverado, making it easier to access and replace the fuel pump.

Using a jack to lift the bed

To access the fuel pump on a 2002 Chevy Silverado, you will need to tilt the bed. This can be done by using a jack to lift the bed and placing blocks of wood to secure it in place. Here is a step-by-step guide on how to do this:

First, remove the tailgate and any necessary torx screws or plastic fasteners around the filler door. Push the assembly into the fender. Next, locate the bolts that attach the bed to the truck. There should be eight of these bolts; four on the driver's side and four on the passenger's side. Using a ratchet and extender, loosen and remove these bolts. You may need to use a breaker bar and have someone help you hold the socket in place if the bolts are difficult to remove.

Once the bolts are removed, you can now lift the bed using a jack. Place a jack under the side with the fuel pump and jack it up until you have enough clearance to access the pump. It is recommended to use two jacks and multiple blocks of wood for added stability and safety. Place the blocks of wood between the frame and the bed, just past the axle. Make sure the blocks are secure and can support the weight of the bed. You can also use jack stands between the bed and chassis for additional support.

With the bed securely lifted, you can now access the fuel pump. Remember to disconnect the fuel line and any electrical connections before removing the pump. When you are finished, simply lower the bed back into place and reattach the bolts.

It is important to take your time and use proper safety precautions when performing this task. Always make sure the vehicle is securely lifted and blocked before proceeding. Additionally, be cautious when working with fuel lines and electrical connections.

Disconnecting the fuel line

Before beginning, ensure you have gathered the necessary tools and safety equipment, such as gloves and eye protection. It is also recommended to work with a partner to ensure a smooth and safe process.

Start by locating the fuel line. This is usually found near the filler neck of the fuel tank, which is the part of the fuel system where you insert the nozzle when filling up your Silverado with gasoline. The fuel line is a metal tube that connects the fuel tank to the engine, supplying it with fuel.

Once you have located the fuel line, place a drip pan or container underneath it to catch any spilled fuel. Fuel can be highly flammable, so ensure you take the necessary precautions to avoid any sparks or open flames during this process.

Using the appropriate wrench or socket, loosen the fitting that secures the fuel line to the filler neck. Be careful not to round off the edges of the fitting by using too much force. You may need to apply some penetrating oil to the threads of the fitting if it is seized or difficult to turn.

After loosening the fitting, carefully disconnect the fuel line from the filler neck. Some fuel may spill out, so be prepared to catch it with your drip pan or container. Once the fuel line is disconnected, plug or cap the open end of the line to prevent any further fuel leakage.

If your Silverado has a fuel return line, which returns excess fuel from the engine back to the tank, be sure to disconnect and cap it as well.

Now that the fuel line is disconnected, you can proceed with the next steps of the fuel pump replacement process. Remember to work safely and carefully when handling fuel, and always dispose of any spilled fuel properly.

If you encounter any issues or complications during this process, it is recommended to consult a professional mechanic or seek advice from a trusted automotive forum or community.

Removing the bolts

To remove the bolts, you will need to locate all the bolts that attach the bed of your Chevy Silverado. There should be eight 18mm bolts in total—four on each side. The bolts at the tail are easy to access, but the ones towards the cab can be more challenging. You will need to use an extension for your ratchet to reach these bolts. The frame has holes from the bottom that will allow you to access them. You may also need a breaker bar and possibly an extra pair of hands to help hold the socket in place or turn the breaker bar.

Once you have located all the bolts, remove the ones on the driver's side completely, and loosen the same four on the passenger side so that you are engaged into the threads by four turns. You can now lift the bed of the truck, which will give you access to the fuel pump. It is important to note that the bed does not have to come all the way off—just lifting it like a dump truck will expose the fuel pump on the top of the tank.

Before lifting the bed, you will also need to remove the tailgate and disconnect the two electrical plugs from the frame to the bed. Additionally, don't forget to undo the fuel line from the filler to the tank (and the breather vent) and the ground wire from the filler to the frame.

To lift the bed, you can use a jack to lift the side with the pump, and then block it securely with wood. Make sure you block it well and use multiple pieces of wood for safety, as you will need to get under the truck to access the fuel pump.

Now that you have removed the bolts and lifted the bed, you can proceed to remove the fuel pump and install the new one.

Replacing the pump

Now that you have access to the fuel tank, you can begin the process of replacing the fuel pump. Here are the steps you need to follow:

• Disconnect the fuel lines and electrical connections: Before you start, make sure to relieve the pressure in the fuel system. You can do this by starting the vehicle and letting it run until it dies. Then, disconnect the fuel lines from the tank and the electrical connections from the pump.
• Remove the old fuel pump: This may involve breaking or cutting the lock ring to release the pump. Be careful not to damage the tank.
• Install the new fuel pump: Insert the new pump into the tank and secure it in place. Make sure to tighten any lock rings or clamps securely.
• Reconnect the fuel lines and electrical connections: Reattach the fuel lines and electrical connections to the new pump. Be sure to check for any leaks before starting the vehicle.
• Test the new fuel pump: Once everything is connected, start the vehicle and check for any leaks or unusual noises. If the pump is working properly, the vehicle should start and run smoothly.

It is important to work cautiously and follow safety procedures when working with fuel systems. Always wear protective gear, such as gloves and eye protection, and have a fire extinguisher nearby in case of any accidents. If you are unsure about any part of the process, it is best to consult a professional mechanic.

Frequently asked questions