Replacing The Fuel Pump On A 1997 K1500: Step-By-Step Guide

If the fuel pump on your 1997 K1500 has stopped working, you can replace it yourself. The fuel pump is mounted at the top of the fuel tank, wired and routed from several connectors at its front. The procedure is not complex, but proper preparation can reduce the time and effort necessary. The average backyard mechanic can replace the fuel pump in about two hours.

How to Replace the Fuel Pump on a 1997 K1500

Disconnect the negative battery cable

Disconnecting the negative battery cable is a crucial first step when working on your car's electrical system or battery. Here's a detailed guide on how to do it safely and effectively:

Locate the Battery

First, you need to find the battery. In most vehicles, the battery is located under the hood, bolted in place near the engine bay's surface. If you can't find it there, check your car's trunk or consult the owner's manual for the exact location.

Identify the Positive and Negative Terminals

Once you've found the battery, identify the positive and negative terminals. The negative terminal is typically marked with a "-" symbol and is usually black, while the positive terminal is marked with a "+" and is often red. Some batteries have plastic caps over these terminals, which you'll need to remove.

Gather the Right Tools

You'll need the right tools to disconnect the battery cables. In most cases, a 10-millimeter open-end wrench or a socket wrench of the same size will do the job. However, it's a good idea to have a wrench kit with multiple socket sizes, as there is no universal size for terminal hardware.

Turn Off the Ignition

Before you begin disconnecting the battery, make sure your car's ignition is turned off. This is an essential safety precaution. It's also recommended to wear eye protection and gloves during this process.

Unbolt and Disconnect the Negative Cable

Now, you can start by unbolting the negative battery cable. Use the appropriate wrench to loosen the nut on the negative terminal, then remove the cable and set it aside, making sure it doesn't touch the battery again. Be careful not to let the wrench touch both the negative and positive terminals simultaneously, as it could short-circuit the battery and create sparks.

Secure the Cable

Once the negative cable is disconnected, push it away from the battery and secure it with zip ties or a battery-disconnect switch to ensure it doesn't accidentally come into contact with the battery terminals again.

By following these steps, you'll be able to safely and effectively disconnect the negative battery cable on your 1997 K1500, allowing you to proceed with further maintenance or repairs. Remember to always prioritize safety when working with your vehicle's electrical system.

Drain the tank

To drain the tank of your 1997 K1500, first remove the negative battery cable. Next, relieve the fuel system pressure. You can do this by referring to the Fuel Pressure Release Procedure.

Now, you can drain the fuel from the tank. You can use a hand-operated pump device to remove the fuel through the filler neck. If your pump is equipped with a static ground wire, make sure to hook this up to a metal part of the gas tank before you begin.

Alternatively, you can disconnect the fuel line at the filter and pump the fuel out using an electric fuel pump and hoses. You can then pump the fuel into a 5-gallon gas can.

If you want to avoid taking the tank down, you can jump the fuel pump relay. To do this, you can string a length of wire from the battery to the fuse box under the dash, plugging it into the fuel pump slot. You can then remove the line at the filter and pump the fuel into a jerry can.

Another option is to use a squeeze bulb siphon hose to drain the tank. This is a cheap investment and can be used multiple times.

Remove the support straps and insulators

To remove the support straps and insulators from your 1997 K1500, you will need to follow a few careful steps. Firstly, loosen the clamp on the hose at the fill pipe and work to remove the tank from the filler neck. This may require some force, but it is important to be careful not to damage any components.

Next, you will need to support the fuel tank. Place something underneath it to hold it up once the straps are removed. Now, you can remove the tank straps and insulator strips. Be sure to have a new set of tank straps ready to install, as the old ones should not be reused.

If the tank straps are stuck, you may need to apply some penetrating oil, such as WD-40, and let it sit for around 20 minutes. You can then try again to remove the bolts, turning them counter-clockwise with a wrench. Be careful not to strip the threads on the bolts. If the bolts are severely corroded, you may need to cut them off with a bolt cutter or a hacksaw.

Once the bolts are removed, carefully lower the fuel tank, being mindful of any attached hoses or wiring. Detach any hoses and wiring, and lift the tank out of the vehicle. Now you can access the fuel pump for replacement.

Disconnect the electrical connections and hoses

To disconnect the electrical connections and hoses on a 1997 K1500, you will need to identify the correct connectors and carefully release them.

Firstly, locate the electrical connector at the fuel pump. This should be a cream-coloured cube with wires entering from the side. There may be a side tab that you can try to slide or squeeze and then pull to release. If this doesn't work, try to lift the tab outward. If the tab breaks, as sometimes happens, you can try to pry it with a pick to work it loose while pulling. If this still doesn't work, you may need to purchase a new connector and transfer the wires.

Alternatively, the electrical connector may be located further upstream, closer to the rear axle, rather than immediately at the fuel pump. In this case, look for a black disconnect and a grounding eyelet.

To disconnect the fuel lines, you will need to identify the type of connector you have. They may be plastic or metal, and there are different methods for releasing each type. You can refer to a document outlining the types of connectors and how to separate them. For metal fuel line connectors, there is a separate set of instructions you can follow.

Finally, to relieve the fuel pressure, start the engine and remove the fuel pump relay from the under-hood fuse block. The engine will stall, and you can then try to start it again. This will relieve most of the pressure in the system.

Remove the fuel pump from the top of the tank

To remove the fuel pump from the top of the tank, you will need to turn all of the screws counterclockwise. Once all the screws have been removed, the pump will be released and can be pulled out vertically. The fuel pump is about 1 foot long.

Before you begin this process, ensure you have disconnected the battery at the positive terminal post, and drained the fuel tank. You can do this by using a siphon or running the vehicle until the fuel is expended.

It is also important to use caution when working around electricity and gasoline.

Frequently asked questions