Replacing Your 2001 Chevy Silverado Fuel Pump: Step-By-Step Guide

If your 2001 Chevy Silverado is not performing as it should, it may be time to replace the fuel pump. This is a significant undertaking but is remarkably easy to do yourself and will save you a lot of money. There are two methods for replacing the fuel pump: removing the bed or dropping the fuel tank. This article will guide you through the steps to replace your fuel pump and offer some tips and tricks along the way.

How to identify a faulty fuel pump

A faulty fuel pump in a 2001 Chevy Silverado can be identified by several symptoms. These may include rough starts or a rough idle, engine sputtering during acceleration, loss of power output, stumbling at higher RPMs, inability to maintain highway speeds, and louder-than-normal whining or humming coming from the fuel tank.

If you are experiencing these issues, there are a few steps you can take to diagnose and address the problem:

• Conduct a fuel pressure check while the engine is running. Low fuel pressure, usually below 50-60 psi, may indicate a faulty fuel pump.
• Examine all electrical connections to ensure that the fuel pump is receiving the necessary current.
• Check for fuel leaks, as these can also cause issues with fuel pump pressure and performance.
• If you have recently replaced the fuel pump, it is possible that the new pump is faulty. Ensure that the power to the pump is sufficient (typically 12 volts) and that the fuel lines are not pinched or blocked.
• If you are still unable to identify the issue, it is recommended to consult a professional mechanic or refer to a fuel pump troubleshooting guide for further guidance.

Two methods for replacing the fuel pump

There are two methods for replacing the fuel pump on a 2001 Chevy Silverado: removing the bed and dropping the fuel tank.

Removing the bed

This method involves unbolting the filler hose from the bed panel, removing the bolts holding the bed down on the driver's side, and loosening the bolts on the passenger side. Then, a jack is placed between the bed and frame rail on the driver's side, and the bed is lifted. This provides access to the top of the fuel tank to change the pump.

Dropping the fuel tank

This method involves the following steps:

Step 1: Relieve fuel line pressure

• Pull the fuel pump relay from the fuse box.
• Start the vehicle and let it run until it shuts down.

Step 2: Lift the truck

• Use the appropriate lifting points and place on jack stands in the manufacturer's recommended locations on level ground.
• If you don't have access to a lift, use four jack stands and lift the entire truck.

Step 3: Remove the fuel filler neck from the tank

• Locate the fuel filler neck on the driver's side of the tank, above the frame.
• Loosen the hose clamp with a stubby flat-head screwdriver and remove the fuel filler neck.

Step 4: Disconnect the fuel tank lines

• Move to the passenger side of the tank and disconnect all lines going into the top of the tank, including the vapor line and the larger supply line.
• Disconnect the two lines above the vapor and supply lines by pushing in the white connector clips and pulling the hoses off.
• Wear safety goggles as gasoline will spill from the lines.

Step 5: Disconnect the power lines to the fuel pump

Disconnect the two quick-release electrical plugs on top of the fuel tank that power the fuel pump.

Step 6: Remove the gas tank straps and lower the tank

• Use a 15 mm socket and ratchet with an extension to remove the gas tank straps.
• Remove the front strap completely and lower the rear strap slowly, as the tank will be heavy.

Step 7: Remove the fuel pump

• Clean around the fuel pump and disconnect the three lines from the fuel pump by squeezing the quick-release clips.
• Turn the locking ring counter-clockwise and remove the fuel pump module.

Step 8: Assemble and install the new fuel pump module

• Assemble the new fuel pump by snapping the float into place and attaching the seal.
• Install the new fuel pump onto the tank and secure it with the locking ring.
• Reinstall the fuel lines and power plugs, and reconnect the filler neck.

Step 9: Reinstall the gas tank

• Lift the fuel tank back into position and reconnect the tank straps.
• Reconnect the power plugs to the fuel pump and the fuel lines.
• Keep the truck lifted and replace the fuel pump relay.
• Start the truck and test the pump. If there are no issues, lower the truck.

Tools and parts needed for the job

The fuel pump in a 2001 Chevy Silverado is located inside the fuel tank. There are two predominant methods for replacing it: removing the bed or dropping the fuel tank. This list of tools and parts assumes you will be dropping the fuel tank.

Tools

• Ratchet with extension and 15 mm socket
• Wire snips and stripper
• Heat gun for wiring shrink wrap
• Shop rags
• A lift or four jack stands
• A hydraulic floor jack (if you don't have an assistant)
• A stubby flat-head screwdriver
• Safety goggles
• A light spray lubricant

Parts

Fuel pump: It is recommended to use an AC Delco brand pump. You will need your VIN number to ensure you get the right pump for your truck's wheelbase and tank size.

Step-by-step guide to replacing the fuel pump

Step 1 – Relieve fuel line pressure

First, pull the fuel pump relay from the fuse box. Then, start the vehicle and let it run until it shuts down. This will relieve gas pressure in the line and the pump. Make sure you do this in a well-ventilated area, free from any heat sources, sparks, or open flames.

Step 2 – Lift the truck

Use the appropriate lifting points and place the truck on jack stands in the manufacturer's recommended locations on level ground. If you don't have access to a lift, use four jack stands and lift the entire truck, rather than just the rear end.

Step 3 – Remove the fuel filler neck from the tank

This step is a little difficult because the fuel filler neck is in a hard-to-reach position. You'll find it on the driver's side of the tank and above the frame. It's a large-diameter hose connected to the tank with a hose clamp. Use a stubby flat-head screwdriver to loosen the hose clamp and remove the fuel filler neck.

Step 4 – Disconnect the fuel tank lines

Move to the passenger side of the tank and disconnect all the lines going into the top of the tank. Start with the vapor line and pull it off from the charcoal overflow tank. Next, disconnect the larger supply line. These two lines have a similar type of connector that you'll squeeze at the base of the connection. Then, disconnect the two lines above the vapor and supply lines. These have white connector clips that need to be pushed in as you pull on the hose.

Step 5 – Disconnect power lines to the fuel pump

There are two quick-release electrical plugs on top of the fuel tank that power the fuel pump. Disconnect these plugs from the pump.

Step 6 – Remove gas tank straps and lower the tank

Use a 15 mm socket and ratchet with a long extension to remove the gas tank straps. Remove the front strap completely. For the rear strap, you'll need an assistant to hold the tank while you remove it, as it will be heavy. If you don't have a helper, you can use a hydraulic floor jack to hold the tank and then lower it carefully.

Step 7 – Remove the fuel pump

When the tank is on the floor, clean around the fuel pump to remove any debris. Then, disconnect the three lines from the fuel pump by squeezing the quick-release clips. Once the hoses are off, turn the locking ring counter-clockwise and pull the pump up and out of the tank.

Step 8 – Assemble and install the new fuel pump module

Your new fuel pump may need minor assembly. Look at the old pump to see how the float and seal are attached. Install the new fuel pump onto the tank and secure it with the locking ring. You can use a light spray lubricant on the seal to make it easier to put back into the tank.

Step 9 – Reinstall lines and rewire harness

Pull the quick-release tabs off the old fuel lines and put them onto the new fuel pump. Reconnect the three fuel lines to the quick-connect tabs. If you have to swap out the wiring harness, be careful not to cut into the wires for the fuel pressure sensor. The existing wires should include two thicker and two thinner wires. Be sure to splice the thick black wires together with the new thick black wires and the thin wires with the thin wires.

Step 10 – Reinstall the gas tank

Lift the fuel tank back into position and reconnect the tank straps. Reconnect the power plugs to the top of the fuel pump and reconnect the fuel lines. Keep the truck in the air while you replace the fuel pump relay and start your truck to test it. If all is well, lower the truck back to the ground and take it for a test drive.

Tips for reassembling the fuel pump

When reassembling the fuel pump, it is important to be methodical and careful. Here are some tips to help you with the process:

• Ensure you have a clean work area and that all the necessary tools are readily available.
• Refer to the old fuel pump for guidance when assembling the new one. Pay close attention to the float and seal placement.
• When attaching the new fuel pump to the tank, use a light spray lubricant on the seal to make it easier to insert into the tank.
• Make sure that the tab on the pump marries to the top of the tank, as this will ensure the pump can only be inserted one way.
• When reinstalling the fuel lines, use quick-release tabs and connect them to the nipples of the new fuel pump.
• If you need to swap out the wiring harness, be cautious not to cut into the wires for the fuel pressure sensor. This harness should always be reused.
• When splicing wires together, consider soldering them for a more secure connection. This will help ensure that you don't have to drop the tank again in the future.
• Use shrink wrap over the spliced area to protect the connections.
• Before lowering the tank back into place, reconnect the power plugs to the top of the fuel pump and the quick-connect wiring harnesses.
• Once the tank is reinstalled, replace the fuel pump relay and start the engine to test the pump before lowering the truck back to the ground.
• If there are any issues, it is easier to check your work while the truck is still lifted.
• If all is well, lower the truck, shut the hood, and take it for a test drive to ensure the fuel pump is functioning correctly.

Frequently asked questions