GM Full-Size Trucks 1980-1987 Repair Guide

Electric Fuel Pump

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REMOVAL & INSTALLATION




WARNING
Before removing the fuel pump allow the engine to cool completely to prevent ignition and possible fire from hot engine components such as the exhaust manifold. Keep a rag handy to soak up any gasoline that might spill on any other components. Immediately dispose of the rag in a container approved for flammable or combustible refuse.

  1. With the engine turned OFF, relieve the fuel pressure at the pressure regulator. See Warning above.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and support the rear of the vehicle on jackstands.
  6.  
  7. Drain the fuel tank, then remove it.
  8.  
  9. Using a hammer and a drift punch, drive the fuel lever sending device and pump assembly locking ring (located on top of the fuel tank) counterclockwise, Lift the assembly from the tank and remove the pump from the fuel lever sending device.
  10.  
  11. Pull the pump up into the attaching hose while pulling it outward away from the bottom support. Be careful not to damage the rubber insulator and strainer during removal. After the pump assembly is clear of the bottom support, pull it out of the rubber connector.
  12.  
  13. To install, reverse the removal procedures.
  14.  

Testing

  1. Secure two sections of 3 /8 in. x 10 in. (steel tubing), with a double-flare on one end of each section.
  2.  
  3. Install a flare nut on each section of tubing. Connect each of the sections into the flare nut-to-flare nut adapter, included in the Gauge Adapter tool No. J-29658-82, or equivalent.
  4.  
  5. Attach the pipe and the adapter assembly to the Gauge tool No. J-29658, or equivalent.
  6.  
  7. Raise and support the vehicle on jackstands.
  8.  
  9. Remove the air cleaner and plug the THERMAC vacuum port on the TBI.
  10.  
  11. Disconnect the fuel feed hose between the fuel tank and the filter, then secure the other ends of the 3 /8 in. tubing into the fuel hoses with hose clamps.
  12.  
  13. Start the engine, check for leaks and observe the fuel pressure, it should be 9-13 psi.
  14.  
  15. Depressurize the fuel system and remove the testing tool. Remove the plug from the THERMAC vacuum port and reconnect the fuel line. Start the engine and check for fuel leaks.
  16.  

 
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