Fuel Pump Replacement
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Fuel Pump Replacement - 1/28/2006 8:43:44 PM
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b45701
Posts: 4
Joined: 1/28/2006
Status: offline
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Lost the pump on my wife's truck yesterday. No pump noise and it won't start. Spark is good and I recently (within 3K miles put all new ignition components on it). It's a 99 with about 100K miles on it. Everything i read on the pumps indicates that’s about normal life for them.
Here’s my questions for those that have done this already.
• I’ve got the tank most the way down, but I can’t figure out how to remove the fuel lines. Is there a special tool to remove the lines? It looks like they push on but they’re not moving coming off and I don’t want to break the plastic they’re connected to. I’ve never see a connector like this, most the cars I tinker with are 30 years older then this truck. Also, there’s a black line toward the front of the tank that will need to come off, haven’t gotten that far though.
• Once the tank is down, is it a matter of rotating the assembly where the fuel lines connect to remove the unit. It kind looks like the sending unit is built into the pump.
• Any other tricks, tips or gotchas you guys have run into performing this task?
Thanks guys, any help is appreciated.
Chuck
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RE: Fuel Pump Replacement - 3/1/2006 10:27:51 PM
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TomSnyder
Posts: 5
Joined: 3/1/2006
Status: offline
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b45701,
Any luck? I, too, have to replace a fuel pump (tomorrow!) on a 99 Tahoe, and was hoping to find tips and tricks here.
Any advice you can give? Did you need any special tools? Did you replace the wiring harness? Etc, etc...
Thanks!
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RE: Fuel Pump Replacement - 3/2/2006 9:19:58 AM
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b45701
Posts: 4
Joined: 1/28/2006
Status: offline
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Tom, it wasn't too bad of a job. My biggest problem was draining 30 gal of fuel. Ended up pulling the fill hose that connects to the tank, drop in a line for suction. If u have an air compressor, take the hose (the end going to the gas can u are about to fill) and cut a slit in it. Then take your sir nozzle and blow air away from the tank. This will create a vacuum for u to get the fuel out. The other problem I had was on the fuel line connections. There’s a goofy little tool that NAPA sells ( I think it was $10) that's supposed to fit between the plastic fuel line on the pump and the actual fuel line itself. I could not get the tool to fit in there and ended up cutting the plastic in the pump. Once this was done I was able to then use the tool and pop out the portion left in the fuel lines. There’s 2 of them, supply and return. Pretty straight forward other then those 2 problems.
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RE: Fuel Pump Replacement - 3/2/2006 12:33:34 PM
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TomSnyder
Posts: 5
Joined: 3/1/2006
Status: offline
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Thanks for the reply.
I've read about the fuel line connectors, and the tool used to disconnect them. I'll take a look at the parts store later today.
The truck has between 1/8 and 1/4 tank of fuel, so I hopefully I won't need to drain it. In fact, I'm thinking this chronically low fuel level contributed to the pump's failure. The Tahoe belongs to my wife's girlfriend, and she said she often lets it get low and even then doesn't put a lot of fuel in it (gas prices). In researching this last night, I've learned that these pumps run too hot when there is not enough fuel in the tank to help keep it cool. In fact, there is a TSB that recommends replacing the harness when the pump is replaced, since so many of the harnesses are heat damaged (TSB 04-06-04-088B JUN 05 Fuel Pump - Connector Replacement Recommendation). By the way, if anyone has the full text of this TSB I would sure appreciate a copy. I found an very similar sounding AC Delco "Service Bulletin" titled "Replacement of Connector When Replacing Fuel Tank Module/Fuel Pump Module" and numbered 05D-J-083. It says that it is applicable to the 1996-2003 Tahoe, so...
You can find a copy of the AC Delco bulletin here.
But, yeah, if anyone has the Chevy TSB 04-06-04-088B...that would be nice. Or any other 1999 Chevy Tahoe TSB's for that matter.
Good tip with the air compressor, too...I'll keep that in mind if I do in fact drain the tank.
I'm supposed to work on this today - just waiting for it to be towed to my house!
Thanks again, fellas...
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