Repair 7

The fourth generation of the 1500 series pickup truck appeared in 1988 and was manufactured until 2000 by Chevrolet. There were a total of eight different versions and cab variations of the 1500. They were powered by reliable V8 engines that required periodic service if parts like the intake manifold gasket would fail.

Instructions

Removal Procedure

1

Mark the relationship of the distributor housing and rotor for proper reassembly. Remove the distributor. Unplug the upper radiator hose at the thermostat housing. Remove the heater hose at the lower intake manifold. Remove the EGR valve and the coolant bypass hose.

2

Pull out the fuel supply and return lines from the rear part of the intake manifold. Unplug the wiring harness and brackets. Remove the throttle cable and bracket. Remove the cruise control cable.

3

Take out the transmission oil level indicator tube. Remove the EGR inlet tube, clamp and bolt. Remove the PCV valve and vacuum hoses. Unscrew the air conditioning compressor. Loosen the A/C compressor mounting bracket and slide forward, but do not remove it. Lay the A/C compressor out of the way. Do not kink the air conditioning lines.

4

Remove the power brake vacuum tube and the rocker arm cover. Remove the generator rear bracket bolt. Take out the intake manifold. Remove the old pieces of gasket from the gasket surfaces. Clean the excessive carbon buildup from inside the exhaust passages and the scale and deposits from the coolant passages. Inspect the manifold for cracks, broken flanges and gasket surface damage.

Installation Procedure

5

Position the new gaskets to the cylinder head with the port blocking plates facing the rear of the engine and "This Side Up" facing up. Install the lower intake manifold on the engine. Apply sealer to the lower intake manifold bolts. Put in the lower intake manifold bolts back in place. Tighten the bolts in three steps. In the first step apply 27 inch pounds of torque. In the second apply 106 inch pound of torque and in the last step tighten the bolts applying 11 foot pounds of torque.

6

Plug in the wiring harness connectors and brackets. Connect the upper radiator hose at the thermostat housing. Install the heater hose at the lower intake manifold. Connect the coolant bypass hose.

7

Install the EGR valve and the valve rocker arm cover. Connect the fuel supply and return lines at the rear of the intake manifold. Plug in the wiring harness and brackets. Install the cruise control cable (if equipped).

8

Install the throttle cable and bracket. Put back the transmission oil level indicator tube. Install the EGR inlet tube, clamp, and bolt. Connect the PCV valve and vacuum hoses. Install the power brake vacuum tube. Install the generator and the bracket bolt (if needed). Install the air conditioning compressor and bracket. Refer to Heating and Air Conditioning. Connect the distributor. Note the relationship of the distributor housing and rotor made at disassembly.

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.