Tools You'll Need:
* Socket Set: Various sizes, including those for the fuel line fittings and possibly the fuel pump retaining bolts.
* Wrench Set: For various bolts and nuts.
* Fuel Line Disconnect Tool: This makes disconnecting the fuel lines much easier and safer than trying to pry them apart.
* Jack and Jack Stands: To safely lift the truck and support it while working underneath.
* Wheel Chocks: For added safety.
* Fuel Pump Removal Tool: This is highly recommended, as it makes removing the pump from the tank much easier and less likely to damage it.
* New Fuel Pump: Ensure it's the correct one for your specific vehicle.
* Fuel-Safe Containers: For catching any spilled fuel.
* Rags or Shop Towels: For cleaning up spills.
* Gloves: To protect your hands.
* Safety Glasses: To protect your eyes.
* Torque Wrench (optional but recommended): For properly tightening bolts.
Procedure:
1. Safety First: Disconnect the negative battery terminal. This prevents accidental sparks.
2. Prepare the Vehicle: Park on a level surface, engage the parking brake, and chock the wheels. Jack up the rear of the truck and securely support it with jack stands.
3. Locate the Fuel Pump: The fuel pump is located inside the fuel tank, usually accessed through a panel under the truck bed. Consult your repair manual for the exact location.
4. Drain the Fuel Tank (Optional but Recommended): This reduces the amount of fuel you'll be working with, making the job safer and cleaner. You can siphon the gas out carefully using a siphon pump or have a shop do it for you.
5. Access the Fuel Pump: Remove the access panel to the fuel tank. This often involves removing bolts or clips.
6. Disconnect Fuel Lines and Electrical Connections: Carefully disconnect the fuel lines using your fuel line disconnect tool. There will be a supply line and a return line. Mark them to ensure correct reconnection. Also, disconnect the electrical connector to the fuel pump. Again, consult your repair manual for the precise location.
7. Remove the Fuel Pump: This is where the fuel pump removal tool is crucial. It's designed to grip and remove the pump from the tank without damaging it. If you don't have one, proceed with extreme caution; you may damage the pump.
8. Install the New Fuel Pump: Carefully install the new fuel pump into the tank, ensuring a proper and secure fit.
9. Reconnect Everything: Reconnect the electrical connector and fuel lines, making sure they're securely fastened. Double-check to ensure all connections are correctly seated.
10. Replace the Access Panel: Reinstall the access panel.
11. Lower the Truck: Carefully lower the truck from the jack stands.
12. Reconnect the Battery: Reconnect the negative battery terminal.
13. Prime the Fuel System: Start the engine and let it run for a few minutes to allow the fuel pump to prime. Check for leaks around the fuel lines.
Important Considerations:
* Repair Manual: A factory service manual for your 1990 Chevy 1500 is highly recommended. It will provide detailed diagrams, specifications, and torque values.
* Fuel Pressure: After replacing the fuel pump, it's a good idea to check fuel pressure using a fuel pressure gauge to ensure the pump is functioning correctly.
* Professional Help: If you're not comfortable performing this repair yourself, take your truck to a qualified mechanic.
This is a general guide. The specific procedures may vary slightly depending on the exact model and configuration of your 1990 Chevy 1500. Always consult a repair manual for your specific vehicle before starting this repair. Improperly performing this repair could lead to a fire or other serious problems.
