Installation Instructions For A Fuel Pump In A 2002 Chevrolet Suburban

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By James Marshall

The Chevrolet Suburban has been in continuous production since 1935. The 2002 model was a sport utility vehicle that also had other marketing names such as the GMC Yukon and Cadillac Escalade. This vehicle had several choices of engines, all of which had fuel injection. The fuel pump in the 2002 Chevrolet Suburban installs into the fuel tank. You must therefore remove the fuel tank from the vehicle to install the fuel pump.

Mute the speaker Listen to this using a male or female voice M/F Disconnect the cable on the negative terminal of the battery to avoid starting the engine accidentally. Remove the filler cap for the fuel tank to relieve the pressure in the fuel tank. Wrap a shop towel around the fuel pressure fitting on the fuel rail and attach a fuel pressure gauge to the fitting. Connect the bleed hose to the pressure gauge and place the open end of the bleed hose into a container approved for gasoline. Open the fuel pressure gauge to relieve the pressure in the fuel system. Remove the fuel pressure gauge from the fitting.

Mute the speaker Listen to this using a male or female voice M/F Place one end of a hose into the filler tube of the fuel tank and place the other end into the gasoline container. Siphon as much fuel as possible from the fuel tank into the container.

Mute the speaker Listen to this using a male or female voice M/F Disconnect the filler pipe and fuel lines from the fuel tank. Support the fuel tank with jack stands and remove the bolts for the fuel tank straps with a socket wrench. Disconnect the fuel tank straps and lower the fuel tank slightly so you can disconnect the harness clip from the cross member and the electrical connections from the fuel tank. Lower the fuel tank completely and remove it from the vehicle.

Mute the speaker Listen to this using a male or female voice M/F Turn the retaining ring for the fuel sender assembly counterclockwise with a fuel tank sending wrench. Remove the retaining ring, and detach the fuel sender assembly from the fuel tank. Discard the gasket on the fuel tank. Pull the fuel strainer from the fuel sender assembly and discard the strainer.

Mute the speaker Listen to this using a male or female voice M/F Detach the electrical connector for the fuel pump. Release the retaining clip for the fuel sensor's electrical connector and detach the fuel sensor's electrical connector. Release the retaining clip for the fuel level sensor and remove the fuel level sensor.

Mute the speaker Listen to this using a male or female voice M/F Install the new fuel pump and gasket by reversing steps two through five. Tighten the bolts for the fuel tank's retaining straps to 30 ft. lbs. with a torque wrench. Tighten the bolts for the cross member to 37 ft. lbs. Fill the fuel tank and replace its filler cap. Connect the cable for the negative terminal on the battery with a socket wrench. Turn the ignition on for two seconds, then turn it off for 10 seconds to pressurize the fuel system. Turn the ignition back on and check for fuel leaks.

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