Replacing Fuel Pump In Chevy Express: Step-By-Step Guide

If you want to change the fuel pump on your 2003 Chevy 2500 HD, you'll first need to remove the fuel tank. Once the tank is out, you can access the fuel pump assembly through the top opening. Before removing the tank, it's recommended to siphon out as much gas as possible. You'll also need to remove the fuel tank fill pipe, evaporative emission (EVAP) canister, and fuel tank shield bolts (if equipped). Disconnect the fuel feed/return pipes from the fuel tank and cap them to prevent contamination. Place a jack under the fuel tank and remove the fuel tank strap bolts and straps. Lower the fuel tank and remove the electrical connections before completely lowering and removing the tank.

Removing the fuel tank

To remove the fuel tank from a 2003 Chevy 2500 HD, you will need to first siphon as much gas as possible out of the tank. Next, remove the fuel tank fill pipe and the evaporative emission (EVAP) canister. If your vehicle is equipped with a fuel tank shield, remove the bolts and the shield itself. Disconnect the fuel feed and return pipes from the tank pipes, then cap the fuel and EVAP pipes to prevent contamination.

Place a suitable jack under the fuel tank, then remove the fuel tank strap bolts and straps. Lower the tank until the electrical connections are accessible, then remove the fuel sending unit connector position assurance (CPA) connector. Disconnect the fuel sending unit and pressure sensor electrical connectors, then completely lower the tank. With the help of an assistant, place the fuel tank in a suitable work area.

Disconnecting the fuel tank shield

To disconnect the fuel tank shield of your 2003 Chevy Express 2500, first, remove the fuel tank fill pipe. Then, remove the evaporative emission (EVAP) canister. If your vehicle is equipped with fuel tank shield bolts, remove them. You can then remove the fuel tank shield.

• Remove the fuel tank fill pipe: This is the first step to gain access to the fuel tank shield.
• Remove the evaporative emission (EVAP) canister: The EVAP canister is part of the vehicle's emissions control system. It needs to be removed to access the fuel tank shield fully.
• Remove fuel tank shield bolts (if equipped): Some Chevy Express 2500 models may have fuel tank shield bolts. If your vehicle has these bolts, be sure to remove them before attempting to remove the shield.
• Remove the fuel tank shield: After completing the previous steps, you should be able to remove the fuel tank shield. It is important to work carefully in this step to avoid damaging any nearby components.

Remember to work safely and refer to a qualified mechanic or a repair manual for further guidance if needed.

Disconnecting the fuel feed/return pipes

To disconnect the fuel feed/return pipes from the fuel tank pipes of your 2003 Chevy Express 2500, you will need to follow these steps:

First, siphon as much gas as possible out of the tank. This will reduce the risk of fuel spillage during the rest of the process. Next, remove the fuel tank fill pipe and the evaporative emission (EVAP) canister. If your vehicle is equipped with a fuel tank shield, remove the bolts securing it in place and take the shield off.

Now you can access the fuel feed/return pipes. Carefully disconnect them from the fuel tank pipes, taking care not to damage any components. Once the pipes are disconnected, cap the fuel and EVAP pipes to prevent possible fuel/EVAP system contamination.

At this point, you can proceed to place a suitable adjustable jack under the fuel tank and begin the process of removing the fuel tank itself.

Lowering the fuel tank

To lower the fuel tank of a 2003 Chevy Express 2500, you will first need to siphon out as much gas as possible. Next, remove the fuel tank fill pipe and the evaporative emission (EVAP) canister. If your vehicle is equipped with a fuel tank shield, remove the bolts and the shield itself. Disconnect the fuel feed and return pipes from the tank and cap them to prevent contamination. Place a suitable jack under the fuel tank and remove the tank strap bolts and straps. You can then start to lower the tank until the electrical connections are accessible. Remove the fuel sending unit connector position assurance (CPA) connector and the fuel sending unit and pressure sensor electrical connectors. Now, with the aid of an assistant, carefully lower the fuel tank completely and place it in a suitable work area.

Disconnecting the fuel sending unit

To disconnect the fuel sending unit of a 2003 Chevy Express 2500, follow these steps:

First, siphon as much gas as possible out of the fuel tank. This will reduce the risk of fuel spillage during the rest of the process. Next, remove the fuel tank fill pipe and the evaporative emission (EVAP) canister. If your vehicle is equipped with a fuel tank shield, remove the bolts holding it in place and take the shield off.

Now, disconnect the fuel feed and return pipes from the fuel tank pipes. It is important to cap the fuel and EVAP pipes at this stage to prevent possible contamination of the fuel and EVAP systems. Place a suitable jack under the fuel tank to support it, then remove the fuel tank strap bolts and lower the tank carefully until the electrical connections are accessible.

Finally, remove the fuel sending unit connector position assurance (CPA) connector and disconnect the fuel sending unit and pressure sensor electrical connectors. With that, you have successfully disconnected the fuel sending unit.

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