Express, Savana, G1500, G2500, G3500, 1998-2005

Fuel Supply Pump

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Removal & Installation



  1. Disconnect the negative battery cables.
  2.  
  3. Locate the pump on the left frame rail and disconnect the electrical lead from the pump and the harness from the pump support bracket.

    Click image to see an enlarged view

    Fig. Fuel pump location-6.5L engines

  4.  
  5. Use two open end wrenches and disconnect the fuel lines at the pump.
  6.  
  7. Remove the pump support bracket screws and remove it from the brake lines.
  8.  
  9. Remove the pump and bracket.
  10.  

To install:

  1. Attach the pump and bracket to the frame rail.
  2.  
  3. Attach the support bracket to the brake lines.
  4.  
  5. Connect the fuel lines to the pump.
  6.  
  7. Connect the harness to the bracket and then connect the lead to the pump.
  8.  
  9. Connect the batteries.
  10.  

  1. Disconnect the negative battery cable.
    NOTE
    Clean the fuel connections before disconnecting them to prevent fuel system contamination. Cap the lines to prevent leakage and contamination.

  2.  
  3. Relieve the fuel system pressure and open the fuel filler cap.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Detach the electrical connector from the pump.
  8.  
  9. Disconnect the fuel lines from the pump, then slide the pump out of its bracket.
  10.  

To install:

  1. Install the pump using new O-rings. Tighten the fittings to 22 ft. lbs. (30 Nm).
  2.  
  3. Engage the electrical connection and install the fuel filler cap.
  4.  
  5. Purge the fuel system of air. Start the vehicle and check for leaks.

    Click image to see an enlarged view

    Fig. Exploded view of the fuel pump assembly mounting-6.6L engines

  6.  

 
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