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    1999 Chevrolet Truck K2500HD 3/4 ton P/U 4WD 5.7L SFI 8cyl

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    Escalade, Suburban, Tahoe, Yukon, Denali, DenaliXL, YukonXL 1999-2005

    Fuel Pump

    Print

    Removal & Installation



    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Properly relieve the fuel system pressure.
    4.  
    5. Drain the fuel from the vehicle.
    6.  
    7. Remove or disconnect the following:

      Negative battery cable
       
      Fuel tank from the vehicle
       
      Locking ring (located on top of the fuel tank) counterclockwise
       
      Lift the fuel pump assembly out of the tank

      Click image to see an enlarged view

      Fig. Lift the fuel pump assembly out of the tank after removing the locking ring

       

    8.  

    To install:

    1. Install or connect the following:

      Fuel pump and secure with locking ring
       
      Fuel tank to vehicle and refill
       
      Negative battery cable
       

    2.  
    3. Run engine and check for fuel leaks.
    4.  

    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Remove or disconnect the following:

      Negative battery cable
       

    4.  
    5. Relieve the fuel system pressure.
    6.  
    7. Drain the fuel tank.
    8.  
    9. Remove or disconnect the following:
      WARNING
      Do not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.



      Fuel tank

      Click image to see an enlarged view

      Fig. Fuel tank-Silverado shown

       



      Fuel sender assembly retaining ring using a fuel tank sending unit wrench. Remove the fuel sender assembly and the seal. Discard the seal.
       

    10.  
    11. Note the position of the fuel strainer on the fuel sender. Support the fuel sender assembly with one hand and grasp the strainer with the other hand. Pull the strainer off the fuel sender. Discard the strainer after inspection. Inspect the strainer. Replace a contaminated strainer and clean the fuel tank.

      Fuel pump electrical connector
       
      Electrical connector retaining clip from the fuel level sensor
       
      Sensor electrical connector from under the fuel sender cover
       
      Fuel level sensor retaining clip
       

    12.  
    13. Squeeze the locking tangs and remove the fuel level sensor.
    14.  
    15. Remove the fuel pressure sensor.
    16.  

    To install:

    1. Install or connect the following:
      NOTE
      Always install a new fuel strainer when replacing the fuel tank fuel pump module.


      NOTE
      The fuel pump strainer must be in a horizontal position when the fuel sender is installed in the tank. When installing the fuel sender assembly, assure that the fuel pump strainer does not block full travel of the float arm.



      Fuel pressure sensor
       
      Fuel level sensor
       
      Sensor retaining clip
       
      Electrical connector to the fuel level sensor
       
      Electrical connector retaining clip to the fuel level sensor
       
      Fuel pump electrical connector
       



      New fuel strainer in the same position as noted during disassembly. Push the strainer on the bottom of the fuel sender until the strainer is fully seated.
       
      New seal on the fuel tank
       



      Fuel sender assembly into the fuel tank
       
      Fuel sender assembly retaining ring
       
      Fuel tank. Install the fuel tank strap attaching bolts. Tighten the bolts to 30 ft. lbs. (40 Nm).
       

    2.  
    3. Refill the fuel tank. Install the fuel filler cap. Connect the negative battery cable.
    4.  
    5. Turn the ignition ON for 2 seconds.
    6.  
    7. Turn the ignition OFF for 10 seconds.
    8.  
    9. Turn the ignition ON .
    10.  
    11. Inspect for fuel leaks.
    12.  

    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Properly relieve the fuel system pressure.
    4.  
    5. Drain the fuel from the vehicle.
    6.  
    7. Remove or disconnect the following:

      Negative battery cable
       
      Fuel tank from the vehicle
       
      Locking ring (located on top of the fuel tank) counterclockwise
       
      Lift the fuel pump assembly out of the tank

      Click image to see an enlarged view

      Fig. Lift the fuel pump assembly out of the tank after removing the locking ring-1999 vehicles

       

    8.  

    To install:

    1. Install or connect the following:

      Fuel pump and secure with locking ring
       
      Fuel tank to vehicle and refill
       
      Negative battery cable
       

    2.  
    3. Run engine and check for fuel leaks.
    4.  

    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Remove or disconnect the following:

      Negative battery cable
       

    4.  
    5. Relieve the fuel system pressure.
    6.  
    7. Drain the fuel tank.
    8.  
    9. Remove or disconnect the following:
      WARNING
      Do not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage tool Joints.



      Fuel tank
       



      Click image to see an enlarged view

      Fig. Fuel pump/sender assembly-2000-01 4.8L, 5.3L and 6.0L engines



      Fuel sender assembly retaining ring using a fuel tank sending unit wrench. Remove the fuel sender assembly and the seal. Discard the seal.
       
      Note the position of the fuel strainer on the fuel sender. Support the fuel sender assembly with one hand and grasp the strainer with the other hand. Pull the strainer off the fuel sender. Discard the strainer after inspection. Inspect the strainer. Replace a contaminated strainer and clean the fuel tank.
       
      Fuel pump electrical connector
       
      Electrical connector retaining clip from the fuel level sensor
       
      Sensor electrical connector from under the fuel sender cover
       
      Fuel level sensor retaining clip
       

    10.  
    11. Squeeze the locking tangs and remove the fuel level sensor.
    12.  
    13. Remove the fuel pressure sensor.
    14.  

    To install:

    1. Install or connect the following:
      NOTE
      Always install a new fuel strainer when replacing the fuel tank fuel pump module.


      NOTE
      The fuel pump strainer must be in a horizontal position when the fuel sender is installed in the tank. When installing the fuel sender assembly, assure that the fuel pump strainer does not block full travel of the float arm.



      Fuel pressure sensor
       
      Fuel level sensor
       
      Sensor retaining clip
       
      Electrical connector to the fuel level sensor
       
      Electrical connector retaining clip to the fuel level sensor
       
      Fuel pump electrical connector
       



      New fuel strainer in the same position as noted during disassembly. Push the strainer on the bottom of the fuel sender until the strainer is fully seated.
       
      New seal on the fuel tank
       



      Fuel sender assembly into the fuel tank
       
      Fuel sender assembly retaining ring
       
      Fuel tank. Install the fuel tank strap attaching bolts. Tighten the bolts to 30 ft. lbs. (40 Nm).
       

    2.  
    3. Refill the fuel tank. Install the fuel filler cap. Connect the negative battery cable.
    4.  
    5. Turn the ignition ON for 2 seconds.
    6.  
    7. Turn the ignition OFF for 10 seconds.
    8.  
    9. Turn the ignition ON .
    10.  
    11. Inspect for fuel leaks.
    12.  

    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Remove or disconnect the following:

      Negative battery cable
       

    4.  
    5. Relieve the fuel system pressure.
    6.  
    7. Drain the fuel tank.
    8.  
    9. Remove or disconnect the following:
      WARNING
      Do not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage tool Joints.



      Fuel tank
       

    10.  
    11. Disconnect the fuel and evaporative emission (EVAP) lines from the fuel tank module.

      Click image to see an enlarged view

      Fig. Fuel pump/sender assembly-2002-06 4.8L, 5.3L and 6.0L engines



      Fuel sender assembly retaining ring using a fuel tank sending unit wrench. Remove the fuel sender assembly and the seal. Discard the seal.
       
      Note the position of the fuel strainer on the fuel sender. Support the fuel sender assembly with one hand and grasp the strainer with the other hand. Pull the strainer off the fuel sender. Discard the strainer after inspection. Inspect the strainer. Replace a contaminated strainer and clean the fuel tank.
       
      Fuel pump electrical connector
       
      Electrical connector retaining clip from the fuel level sensor
       
      Sensor electrical connector from under the fuel sender cover
       
      Fuel level sensor retaining clip
       

    12.  
    13. Squeeze the locking tangs and remove the fuel level sensor.
    14.  
    15. Remove the fuel pressure sensor.
    16.  

    To install:

    1. Install or connect the following:
      NOTE
      Always install a new fuel strainer when replacing the fuel tank fuel pump module.


      NOTE
      The fuel pump strainer must be in a horizontal position when the fuel sender is installed in the tank. When installing the fuel sender assembly, assure that the fuel pump strainer does not block full travel of the float arm.



      Fuel pressure sensor
       
      Fuel level sensor
       
      Sensor retaining clip
       
      Electrical connector to the fuel level sensor
       
      Electrical connector retaining clip to the fuel level sensor
       
      Fuel pump electrical connector
       



      New fuel strainer in the same position as noted during disassembly. Push the strainer on the bottom of the fuel sender until the strainer is fully seated.
       
      New seal on the fuel tank
       



      Fuel sender assembly into the fuel tank
       
      Fuel sender assembly retaining ring
       
      Fuel tank. Install the fuel tank strap attaching bolts. Tighten the bolts to 30 ft. lbs. (40 Nm).
       

    2.  
    3. Refill the fuel tank. Install the fuel filler cap. Connect the negative battery cable.
    4.  
    5. Turn the ignition ON for 2 seconds.
    6.  
    7. Turn the ignition OFF for 10 seconds.
    8.  
    9. Turn the ignition ON .
    10.  
    11. Inspect for fuel leaks.
    12.  

    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Remove or disconnect the following:

      Negative battery cable
       

    4.  
    5. Relieve the fuel system pressure.
    6.  
    7. Drain the fuel tank.
    8.  
    9. Remove or disconnect the following:
      WARNING
      Do not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.



      Fuel tank

      Click image to see an enlarged view

      Fig. Exploded view of the fuel pump assembly mounting

       



      Fuel sender assembly retaining ring using a fuel tank sending unit wrench. Remove the fuel sender assembly and the seal. Discard the seal.
       

    10.  
    11. Note the position of the fuel strainer on the fuel sender. Support the fuel sender assembly with one hand and grasp the strainer with the other hand. Pull the strainer off the fuel sender. Discard the strainer after inspection. Inspect the strainer. Replace a contaminated strainer and clean the fuel tank.

      Fuel pump electrical connector
       
      Electrical connector retaining clip from the fuel level sensor
       
      Sensor electrical connector from under the fuel sender cover
       
      Fuel level sensor retaining clip
       

    12.  
    13. Squeeze the locking tangs and remove the fuel level sensor.
    14.  
    15. Remove the fuel pressure sensor.
    16.  

    To install:

    1. Install or connect the following:
      NOTE
      Always install a new fuel strainer when replacing the fuel tank fuel pump module.


      NOTE
      The fuel pump strainer must be in a horizontal position when the fuel sender is installed in the tank. When installing the fuel sender assembly, assure that the fuel pump strainer does not block full travel of the float arm.



      Fuel pressure sensor
       
      Fuel level sensor
       
      Sensor retaining clip
       
      Electrical connector to the fuel level sensor
       
      Electrical connector retaining clip to the fuel level sensor
       
      Fuel pump electrical connector
       



      New fuel strainer in the same position as noted during disassembly. Push the strainer on the bottom of the fuel sender until the strainer is fully seated.
       
      New seal on the fuel tank
       



      Fuel sender assembly into the fuel tank
       
      Fuel sender assembly retaining ring
       
      Fuel tank. Install the fuel tank strap attaching bolts. Tighten the bolts to 30 ft. lbs. (40 Nm).
       

    2.  
    3. Refill the fuel tank. Install the fuel filler cap. Connect the negative battery cable.
    4.  
    5. Turn the ignition ON for 2 seconds.
    6.  
    7. Turn the ignition OFF for 10 seconds.
    8.  
    9. Turn the ignition ON .
    10.  
    11. Inspect for fuel leaks.
    12.  

     
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