Fuel Pump replacement on GMT800 Pickup

Black02Silverado

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OK, I finally got around to changing out my fuel pump. The old one was only putting out 48psi of pressure at idle and it is supposed to be 50psi or above. The truck was not wanting to start on the first turn of the key just about every time when it was ran for a while.

I ordered this AC Delco pump off Rock Auto for $189, that included a discount they had offered. I also called up a GM dealer, basically MS3DALE from here and on GM-T to make sure I got the correct pump. I provided Rich with my VIN and he hooked me up to the correct part number pump to get. There are at least 5 different pumps from what I can tell so make sure you do your homework.

Pulling the bed is a piece of cake, just like all the YouTube videos out there. Just remove the six bolts that are 18mm from under the truck, the two screws that hold the fuel filler neck in place and two plugs back by the bumper on the drivers side to disconnect the light harness. Then just find some friends to help lift it off. I was able to get it off with the help of one other person, but putting it on I had three others help me. It made it easier as to not scratch the back part of the bed that goes down below and in from of the rear bumper and the cab with the front of the bed.

The pump came with really clear and easy to understand directions. I had to cut one of my harness plugs off and install the new updated plug. My wires matched, purple to purple, grey to grey, black to black and orange to orange. The provided connectors work really well and when you use a heat gun to heat shrink them, a small goo comes out around the wire, that way you know you got a good weather tight seal. Then I just rapped them back up with some electrical tape and put them back in the plastic cover and hooked everything back up.

I did run into a small snag. When I pulled the plumbing off the old pump, the center one, which is the Evap line, it was hard to come off and when it did it jerked hard and I snapped the line as you can see in the one picture. I got on the phone to the dealer and one was in stock about an hour away. Turns out that thing is $108 from a dealer on online for $55. I decided to fix it myself and as you can see I just used some 1/4"urethane fuel hose and a "T" fitting from the local Car Quest store. Works like a champ and the hose fits really tight on the lines. Matter of fact I tried to pull it back off the "T" fitting and it would not come off. The barbs are doing their job. Since it is just a vent line and no pressure I'm not worried about it leaking.

Other than that little snag, it is really easy to accomplish. Hardest part was getting help over to remove the bed.

So far the truck starts really quick and first time. So it seems that was my problem with the hard starting.

Here are some pictures.

Here you have to remove the filler next bolts, then once it is loose, I tied it down to the spring to keep it out of the way.



This is one of the eight bolts holding down the bed, size 18mm. My air wrench made short order in getting them out.



Here is the electrical plugs, the 2 that need to be removed are in the middle, one on top and one on the bottom.



Bed removed from truck.



I just set it down on my jack stands.



The nice mess of mulch and stuff on top of the tank.




What the plugs look like after the bed was removed.



New pump installed and connected to new harness, just needed to heat shrink and wrap.



My screw up! I have to say, it seems I can't do anything with out something adding some excitement to the mix. :lol:



Here is the fix to my screw up!



Hope this helps the next person that might want to tackle this. I can say to keep from breaking that middle line, you might want to pull it out of the clamps that hold it down to the side of the fuel tank, to give it some room to move. I didn't do that and I think that was why it broke.
 
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daddy

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Great write-up. I wish I could take the bed off the white Tahoe. It's having the same difficulties.
 

Black02Silverado

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OldCracker29

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:thumbs: Nice write up with pics. I have a feeling this will be an upcoming project of mine for someone else to do. I'm just not able to work on shit like I used to be able to. :(
 

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