Replacing Fuel Pump In '05 Chevy Colorado: Step-By-Step Guide

Replacing the fuel pump on a 2005 Chevy Colorado can be a challenging task. The fuel pump is located inside the fuel tank, and accessing it typically requires removing the fuel tank or lifting the bed of the truck. Some people suggest cutting a hole in the bed of the truck to access the fuel pump, but this may not be feasible for all models, especially crew cab models where the pump is located under the cab. Before starting the replacement, it is important to check the fuel pressure and fuses to confirm that the fuel pump is faulty. When replacing the fuel pump, it is recommended to use OEM parts and to clean the fuel tank and replace the fuel filter and strainer.

Check for fuel pressure issues

To check for fuel pressure issues, you can start by checking the fuses and relays, and then conducting a fuel pressure test. The fuel pressure for a 2005 Chevy Colorado with a 5-cylinder engine is between 50-57 psi (pounds per square inch) when the key is on and the engine is off. If there is no hum from the fuel tank and no fuel pressure, check the fuse labelled "FUEL PMP" in the under-hood fuse block. If the fuse is good and there is still no fuel pressure or hum, then the fuel pump may be faulty.

If there is a hum from the tank but the fuel pressure is low, check the fuel filter and make sure it is not clogged. If the filter is clear, remove the vacuum line from the pressure regulator, which is under the hood on the side of the fuel rail. If there is fuel in the vacuum line, the regulator is faulty. If the vacuum line is dry and the filter is not clogged, the fuel pump may need to be replaced.

If you are experiencing issues with your fuel pressure, it is also recommended to check for a fuel leak. If there is a fuel leak, do not drive the vehicle as this poses a fire risk.

Check the fuse

To check the fuse of the fuel pump on a 2005 Chevy Colorado, follow these steps:

First, locate the fuse block. For the Chevy Colorado, the fuse block is located under the hood. Once you have found the fuse block, look for the fuse labelled "FUEL PMP". This fuse is a 15a fuse.

Remove the "FUEL PMP" fuse and inspect it for any signs of damage or wear. A blown fuse will typically have a broken wire or a burnt smell. If the fuse appears damaged, replace it with a new one of the same type and rating.

If the fuse looks intact, check for continuity using a multimeter or a test light. A fuse with continuity is still functional, while a blown fuse will show no continuity.

If you find that the "FUEL PMP" fuse is blown or not functioning, replace it with a new one. Recheck the fuse block for power after replacing the fuse. If there is still no power to the fuel pump, there may be an issue with the wiring or the fuel pump itself.

It is important to note that checking the fuse should be done with the key in the "ON" position but without starting the engine. Additionally, always refer to the owner's manual or a trusted mechanic for specific instructions and safety precautions when working on your vehicle.

Check the fuel filter

To check the fuel filter on a 2005 Chevy Colorado, you'll first need to locate it. The fuel filter is underneath the driver's side of the truck, towards the rear of the cab.

Now, before you do anything, remove the fuel pump fuse from the fuse box. It's a small 15-amp fuse located between the fuel pump relay and the centre mounting bolt, fuse #13. Next, start the truck and let it run until it dies. This will only take 2-3 seconds, as it will be running off the leftover gas in the lines. Turn off the truck after it runs out of gas.

Now, remove the gas cap to relieve any extra pressure in the gas tank. Jack up the truck so you can get underneath it. You'll want to jack it up about a foot to give you room to work.

Look at the connectors on the hoses attached to the filter ends. You'll see two little plastic squares. Push those in to remove the lines from the filter. It's a bit like a child-proof cap on a medicine bottle. Remove the inlet hose first (the one that comes over the top of the filter). That way, you can leave the outlet hose connected and reduce your fuel loss. Have a rag handy, because you will lose some fuel from both the hose and the filter.

Now you can check the fuel filter. If it's dirty, it will need to be replaced.

Remove the fuel tank

To remove the fuel tank from a 2005 Chevy Colorado, you have two options: lowering the tank or lifting the bed.

Lowering the tank:

• Disconnect all the lines on the tank to remove the pump/sender.
• This method is not recommended if you have a crew cab model, as the pump is under the cab.
• This method is also more challenging if the tank is full, as it will be heavy.

Lifting the bed:

• Unbolt the bed and lift it off the frame.
• This is easier with two people and can be done by hand.
• You will need to unhook the wiring harness from the brake lights and unbolt the gas tank filler neck from the bed.
• This method gives you more room to work and access the fuel lines and connectors.
• If you don't want to completely remove the bed, you can lift it up on one side and block it in position.

Before deciding which method to use, check the condition of the components. For example, are the fasteners corroded, and will the straps need to be replaced? If you decide to lower the tank, you will need a suitable support for it, even if it is almost empty.

Disconnect the fuel lines

To disconnect the fuel lines of your 2005 Chevy Colorado, you will first need to decide whether to drop the tank or lift the bed.

If you decide to drop the tank, you will need to crawl under the truck and assess the condition of the components. Check the fasteners on the tank for corrosion, and ensure that the straps and fill tube do not need to be replaced. If you go down this route, you will need a suitable support for the tank, even if it is almost empty. When reinstalling the tank, you will need something to hold it up while you reconnect the fuel lines and connectors.

If you decide to lift the bed, you will need to remove all the fasteners on the left side and loosen the right side, ensuring that the wiring and the bed will clear at the aft end. Remove the fasteners holding the fill tube to the bed. This method will give you full access to work on the fuel lines and connectors, and you can perform an operational and leak check while you still have full access. However, you will need to take all necessary precautions to ensure that the bed does not return to its normal position while you are still under the truck.

Whichever method you choose, you will need to disconnect the fuel lines from the tank. To do this, first locate the fuel lines and connectors. You may need to use penetrating oil to loosen any corroded or seized fasteners. Once the lines are loose, carefully pull them apart, being careful not to spill any fuel. Have some rags or a drip pan ready to catch any drips or spills. Once the lines are disconnected, you can proceed to remove the fuel pump.

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