Here's a general overview. Specific steps may vary slightly depending on your truck's engine and configuration. Always consult a repair manual specific to your 1993 Chevy Silverado extended cab and engine for detailed instructions and diagrams. A Haynes or Chilton manual is a good investment.
Tools You'll Likely Need:
* Socket set (metric)
* Wrenches (metric)
* Screwdrivers (Phillips and flathead)
* Fuel pump pliers (or a similar tool to disconnect fuel lines)
* Fuel line disconnect tool (optional, but highly recommended)
* Jack and jack stands (essential for safety)
* Wheel chocks
* Safety glasses
* Gloves
* Rags
* New fuel pump (ensure it's the correct one for your truck)
* New fuel filter (recommended to replace at the same time)
* Torque wrench (recommended for proper tightening)
* Shop towels or absorbent material
General Steps:
1. Safety First: Disconnect the negative battery cable.
2. Lower the Fuel Tank: This is usually the most labor-intensive part. You'll likely need to:
* Access the fuel tank straps located under the truck.
* Carefully loosen the straps. Some trucks require removing the bed or parts of the bed. Consult your repair manual.
* Lower the tank using a jack and jack stands to support it. Be careful not to damage the fuel lines or electrical connections. The tank might be heavy, so have a helper if possible.
3. Disconnect Fuel Lines and Electrical Connector:
* Use fuel line pliers or a disconnect tool to carefully separate the fuel lines from the fuel pump. Have a container ready to catch any remaining fuel. It is crucial to relieve pressure in the fuel system before disconnecting lines. The best way to do this is by cranking the engine briefly until it stops (due to fuel pump failure).
* Disconnect the electrical connector from the fuel pump.
4. Remove the Fuel Pump Assembly: This usually involves removing the access plate to the fuel pump. You might need to unbolt the fuel pump assembly from the tank. The pump assembly may be secured with a retaining ring.
5. Replace the Fuel Pump: Install the new fuel pump, ensuring the gasket is properly seated.
6. Reinstall the Fuel Pump Assembly and Access Plate: Carefully reassemble everything in reverse order.
7. Reconnect the Fuel Lines and Electrical Connector: Ensure all connections are secure and tight.
8. Raise the Fuel Tank: Carefully raise the fuel tank back into place and secure the straps.
9. Reconnect the Battery: Reconnect the negative battery cable.
10. Prime the Fuel System (Important): You may need to crank the engine for a few seconds (with the ignition on, but not starting) to prime the fuel pump and fill the lines. This is particularly important with modern fuel injection systems.
11. Start the Engine: Once the fuel system is primed, start the engine and check for leaks. Look for fuel leaks around all connections. Listen for the fuel pump to run.
12. Test Drive: Take the truck for a short test drive to verify proper operation.
Important Considerations:
* Fuel Pressure: Some fuel systems require a fuel pressure regulator reset. Check your repair manual.
* Proper Torque: Use a torque wrench to ensure proper tightening of all bolts and connections to prevent leaks.
* Cleanliness: Keep the area clean to prevent debris from entering the fuel system.
This is a complex procedure. If you're not comfortable performing this repair yourself, it's best to take your truck to a qualified mechanic. Improperly installing a fuel pump can lead to serious safety hazards. Remember to consult your repair manual for vehicle-specific instructions.
