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

If your 2006 Chevy Colorado is not performing as it should, you may need to replace the fuel pump. This is a complex job that is best performed by a professional mechanic, but it is possible to do it yourself. To replace the fuel pump, you will need a ratchet with an extension and a 15mm socket, wire snips and strippers, a heat gun for wiring shrink wrap, and plenty of shop rags for spilled fuel. The process involves relieving the fuel line pressure, lifting the truck, removing the fuel filler neck from the tank, disconnecting the fuel tank lines and power lines to the fuel pump, removing the gas tank straps and lowering the tank, removing the fuel pump, assembling and installing the new fuel pump module, reinstalling the lines and rewiring the harness, and reinstalling the gas tank.

Removing the bed vs dropping the fuel tank

When it comes to accessing the fuel pump on a 2006 Chevy Colorado, there are two main approaches: removing the bed or dropping the fuel tank. Here's a detailed comparison of these two methods to help you decide which one to choose.

Removing the Bed

This method involves unbolting and lifting the bed of the truck off the frame. It is considered easier and quicker than dropping the fuel tank. Here are the steps and considerations for this process:

• Disconnecting the wiring harness from the brake lights.
• Unbolting the gas tank filler neck from the bed.
• Removing the tailgate.
• Lifting the bed: This task can be done by two people, but having four individuals is recommended for better control and to avoid any potential mishaps. The bed is surprisingly light, but ensure you have enough help to handle it safely.
• Blocking the bed: If you don't want to completely remove the bed, you can lift it and block it in a position 6 to 12 inches above its normal mounting position. This will give you the clearance needed to access the fuel pump.

Dropping the Fuel Tank

Dropping the fuel tank is a more cramped and challenging approach, but it can be done by one person. Here are the key steps and considerations:

• Disconnecting the filler neck and vent.
• Jacking up the tank: Place a jack under the tank and slowly release the straps to lower it.
• Disconnecting fuel lines and wires: Once the tank is lowered, you'll have access to disconnect the fuel lines and wires to the pump.
• Replacing the pump: While you have access to the tank, it is recommended to replace the pump to avoid future issues.
• Corrosion: If your truck is exposed to road salt, be prepared for corroded mount bolts and straps, which can make the job more difficult.

In summary, removing the bed provides better access and is generally preferred if you have the help of a few people. Dropping the fuel tank is a more confined task but can be managed by a single person with the right tools and preparation.

Disconnecting the fuel filler neck

Once the hose clamp is loose, you can proceed to remove the fuel filler neck. Grip the neck firmly and pull it straight off. It should come off without too much force. If you encounter resistance, check that the hose clamp has been sufficiently loosened and try again. Be cautious not to damage the surrounding components or the fuel filler neck itself.

After removing the fuel filler neck, it's important to set it aside safely. Place it in a secure location where it won't be accidentally knocked over or damaged. You may also want to have some shop rags ready to wipe up any spilled fuel.

Now that the fuel filler neck is disconnected, you can proceed to the next step of removing the fuel tank. Remember to work in a well-ventilated area and take the necessary precautions when working with fuel to ensure your safety.

Disconnecting the fuel tank lines

Step 1 – Prepare the Work Area

Before beginning any work, ensure you are in a well-ventilated area, free from any heat sources, sparks, or open flames. Working on a fuel system can be dangerous, so take the necessary precautions. Do not smoke while working. It is also recommended to wear safety goggles to protect your eyes from any spilled gasoline.

Step 2 – Locate the Fuel Tank Lines

The fuel tank lines are located on the passenger side of the tank. There will be multiple lines connected to the top of the tank that need to be disconnected. These include the vapor line, the supply line, and two additional lines above them.

Step 3 – Disconnect the Vapor Line

Start by disconnecting the vapor line from the charcoal overflow tank. This line, along with the supply line, can be disconnected by squeezing at the base of the connection. The line should pop off with a little wiggling. Be prepared for some gasoline to spill, as there will still be some pressure left in the line.

Step 4 – Disconnect the Supply Line

After the vapor line is disconnected, move on to the larger supply line. Use the same technique of squeezing the base of the connection to pop it off. Again, be cautious of any remaining fuel pressure that may cause spills.

Step 5 – Disconnect the Remaining Lines

The final two lines above the vapor and supply lines will require the use of both hands. These lines have white connector clips that need to be pushed in simultaneously while pulling on the hose. With a firm grip, you should be able to disconnect these lines easily.

By following these steps, you will have successfully disconnected the fuel tank lines, which is a crucial step in replacing the fuel pump on your 2006 Chevy Colorado. Remember to stay safe and always be cautious of any remaining fuel pressure when working on fuel system components.

Disconnecting the power lines to the fuel pump

Step 1: Safety First

Before beginning any work on your vehicle, it is essential to prioritize your safety. Make sure you are working in a well-ventilated area, free from any potential sources of ignition, such as sparks, open flames, or cigarettes. Working with fuel can be dangerous, so taking these precautions is crucial.

Step 2: Prepare Your Tools

To disconnect the power lines to the fuel pump, you will need a ratchet with an extension and a 15 mm socket. Having shop rags on hand is also recommended to deal with any spilled fuel.

Step 3: Locate the Power Lines

The power lines to the fuel pump can be found on top of the fuel tank. There are two quick-release electrical plugs that provide power to the fuel pump.

Step 4: Disconnect the Power Lines

Using your ratchet and socket, carefully disconnect the two quick-release electrical plugs from the fuel pump. Be gentle but firm to avoid any damage to the plugs or the fuel pump itself.

Step 5: Clean Up

Once the power lines are disconnected, it is important to clean up any spilled fuel with your shop rags. Ensure that you dispose of the rags appropriately, as they will be soaked with fuel.

Step 6: Lower the Fuel Tank

After disconnecting the power lines, you will need to lower the fuel tank to access the fuel pump fully. Use a hydraulic floor jack to support the tank and lower it carefully. It is helpful to have an assistant to hold the tank while you work, as it will be heavy.

By following these steps, you can safely and effectively disconnect the power lines to the fuel pump on your 2006 Chevy Colorado. Remember always to put safety first when working on your vehicle and to dispose of any hazardous materials properly.

Removing the fuel pump

To remove the fuel pump from a 2006 Chevy Colorado, you can either remove the bed or drop the fuel tank. Here is a step-by-step guide on how to remove the fuel pump by dropping the fuel tank:

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. This will relieve the gas pressure in the line and the pump. Ensure you are working in a well-ventilated area, away from any heat sources, sparks, and 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.

Step 3: Remove the fuel filler neck from the tank

This step can be a little tricky as the fuel filler neck is in a difficult position to access. On the driver's side of the tank and above the frame, you will find the fuel filler neck. Loosen the hose clamp with a stubby flat-head screwdriver and remove the 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 then disconnect the larger supply line. These lines have connectors that you'll need to squeeze at the base to pop them off. There are two more lines above these that will need to be disconnected as well. These have white connector clips that need to be pushed in while pulling on the hose.

Step 5: Disconnect power lines from 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 the gas tank straps and lower the tank

Use a 15 mm socket and ratchet with a long extension to remove the gas tank straps. For the rear strap, you may need an assistant to hold the tank while you remove it, as it will be heavy. Alternatively, you can use a hydraulic floor jack to support the tank while you remove the straps.

Step 7: Remove the fuel pump

Once the tank is on the floor, clean around the fuel pump to remove any debris, leaves, or rust. Disconnect the three lines from the fuel pump by squeezing the quick-release clips and pulling the hoses off. Turn the locking ring counter-clockwise to remove it, and then pull the fuel pump module out of the tank.

By following these steps, you will be able to successfully remove the fuel pump from your 2006 Chevy Colorado.

Frequently asked questions