Repair 7

How to Change the Fuel Pump on a 2000 Chevy 1500

The Chevrolet C/K 1500 is a line of full-size pickup trucks made from 1960 to 2000. A "C" designator indicates a 2-door vehicle and a "K" designator indicates a 4-door vehicle. The "1500" designator indicates that its a 1/2-ton truck. The 2000 Chevy 1500 has a fuel pump module inside the fuel tank that contains a fuel pump and other fuel system components. Changing the fuel pump on this vehicle therefore requires you to remove the fuel tank and separate the fuel pump from the rest of the fuel pump module.

Instructions

1

Disconnect the cable from batterys negative terminal with a socket wrench. Loosen the filler cap on the fuel tank and connect a fuel pressure gauge to the fuel pressure valve on the fuel rail. Place the bleed hose for the fuel pressure gauge into a gasoline-approved container. Open the valve on the fuel pressure gauge to drain fuel into the container. Detach the fuel pressure gauge from the fuel pressure valve.

2

Drain the fuel from the fuel tank and disconnect the fuel lines from the fuel tank. Support the fuel tank with a jack stand and disconnect the bolt for the fuel tank retaining strap with a socket wrench. Lower the fuel tank halfway to the ground. Remove the harness clip for the cross member on the underside of the vehicle and disconnect the electrical connectors for the fuel tank. Lower the fuel tank completely and remove it from the vehicle.

3

Turn the retaining ring on the fuel sender assembly counterclockwise with a fuel tank sending unit wrench. Detach the retaining ring and remove the fuel sender assembly and seal from the fuel tank. Discard the seal. Pull the fuel strainer from the fuel sender assembly and discard the fuel strainer. Clean the surface of the fuel tank around the mounting area for the fuel sender assembly.

4

Disconnect the electrical connector for the fuel pump. Detach the retaining clip for the electrical connector on the fuel level sensor and disconnect the electrical connector. Squeeze the tangs on the retaining clip for the fuel level sensor and disconnect the fuel level sensor from the fuel pump. Remove the fuel pressure sensor from the fuel pump.

5

Install the new fuel pump by performing steps 2 through 4 in reverse order. Connect a new fuel strainer to the fuel pump by pushing it into the bottom of the fuel pump until the fuel strainer is fully seated. Ensure that the strainer does not interfere with the movement of the float arm. Install a new seal on the fuel tank. Tighten the attaching bolts on the fuel tank strap to 30 foot-pounds with a torque wrench.

6

Refill the fuel tank and fasten the filler cap on the fuel tank. Connect the cable to the negative terminal on the battery. Turn the ignition on for two seconds, then turn it off for 10 seconds to pressurize the fuel system. Turn the ignition on and check the fuel system for leaks.