Replacing The Fuel Pump In A '97 Suburban: A Step-By-Step Guide

Replacing the fuel pump on a 1997 Chevrolet K1500 Suburban can be a challenging task. The process involves disconnecting the negative battery cable, draining the fuel tank, and raising the rear of the vehicle. One must also remove components such as the filler neck clamp, vent tube hose, gauge hose, support straps, insulators, and fuel tank shield. It is crucial to relieve the fuel system pressure before beginning any work on fuel components to ensure safety. When reinstalling the new fuel pump, it is important to inspect the fuel pump attaching hose, rubber sound insulation, and strainer for any signs of damage or deterioration. Additionally, one should be careful not to bend or fold the fuel strainer during installation, as this can restrict fuel flow.

Disconnect the negative battery cable

Disconnecting the negative battery cable is the first step in replacing the fuel pump on a 1997 K1500 Suburban. This is a critical safety precaution as it helps prevent the risk of fire and serious injury by safely releasing the pressurized fuel in the system.

To disconnect the negative battery cable, first locate the negative terminal. It is usually black and smaller in cross-section compared to the positive terminal, which is typically red. Ensure that you have the correct cable by checking the cable length, as well as the number and gender of the cable's connectors and terminals.

Once you have identified the negative battery cable, follow these steps:

• Put on safety gear, such as gloves and eye protection, to protect yourself from any battery acid.
• Loosen the nut or bolt that secures the negative battery cable to the negative terminal using the appropriate size wrench or socket.
• Carefully remove the cable from the terminal, ensuring that it does not touch any metal parts of the vehicle.
• If needed, clean the terminal and cable end with a wire brush to remove any corrosion or residue.
• Apply a light coat of battery terminal corrosion inhibitor or petroleum jelly to the threads of the terminal to prevent future corrosion.

It is important to note that you should always disconnect the negative battery cable first when working on any electrical system in your vehicle. Additionally, be sure to store the disconnected cable in a safe place where it cannot accidentally come into contact with the battery terminal.

Drain the tank

To drain the tank of a 1997 K1500 Suburban, first, loosen the fuel filler cap to relieve the fuel tank vapour pressure. Next, raise the vehicle and loosen the fuel filler hose clamp at the tank. Disconnect the fuel filler hose from the fuel filler pipe. You can then use a hand or air-operated pump to drain the fuel through the filler hose.

Alternatively, you can drain the tank by disconnecting the fuel filter and attaching a rubber hose with a clamp to the filter. The other end of the hose should be placed in a gas can. Turn the ignition key to the 'on' position for two seconds, then to the off' position for ten seconds. Repeat this process again, then turn the ignition key to the 'on' position and the fuel pump should drain the tank.

Remove the support straps and insulators

To remove the support straps and insulators of a 1997 K1500 Suburban, you must first disconnect the negative battery cable and drain the tank. Next, raise the rear of the vehicle and support it with jack stands. Remove the clamp on the filler neck and the vent tube hose. If your vehicle is equipped with a gauge hose attached to the frame, remove it.

Now, while supporting the tank securely, remove the support straps and insulators. If your vehicle is equipped with a fuel tank shield, remove it.

Once the support straps and insulators have been removed, you can continue with the fuel pump replacement procedure.

Remove the fuel tank

To remove the fuel tank from a 1997 K1500 Suburban, you will first need to drain the fuel from the tank. Next, locate the skid plate around the tank and remove the bolts holding it in place. You will then need to release the rubber hose from the tank inlet at the filler neck and stuff a rag into the opening to prevent debris from falling in.

Now, you can remove the ground wire from the fuel pump that is attached to the frame rail. This step is not mandatory, but it will make the process easier and reduce the risk of breaking something.

To lower the tank, you can use a floor jack and a piece of plywood to prevent damage to the tank. Remove the support strap bolts with an impact gun or an air ratchet if possible, as this will be quicker. Slowly lower the tank with the floor jack, wiggling it gently to get it out from between the frame rails. You may also need to pry it away from the floor pan.

Once the tank is lowered, you will need to disconnect the fuel lines and wires running to the sending unit. Be careful, as the fuel lines may be rusted and brittle. Finally, drag the tank out from under the truck.

Remove the fuel sender assembly

To remove the fuel sender assembly from a 1997 K1500 Suburban, you will need to first disconnect the negative battery cable. Next, relieve the fuel system pressure. You can refer to the fuel system relief procedure in your vehicle handbook for this.

Now, raise the vehicle and support it safely with jack stands. Drain the fuel system and remove the fuel tank, referring to the manufacturer's instructions for this model.

Be careful not to damage the rubber insulator or strainer during this process. It is also important to inspect the fuel pump attaching hose, rubber sound insulation, and strainer for any signs of damage or deterioration.

Frequently asked questions