Before You Begin:
* Safety First: Disconnect the negative battery cable. Fuel is highly flammable. Work in a well-ventilated area, away from open flames.
* Gather Tools: You'll need a variety of tools, including sockets, wrenches, screwdrivers, a fuel pump removal tool (often a specialized strap wrench), jack stands, safety glasses, and gloves. Consult your repair manual for the specific tools required.
* Obtain Replacement Parts: Get a new fuel pump assembly (this usually includes the sending unit, fuel filter, and pump). Consider replacing the fuel filter separately as well.
* Proper Disposal: Dispose of old fuel and fuel-soaked parts responsibly, according to local regulations.
General Steps (These are general guidelines and may vary):
1. Vehicle Preparation: Park the Tahoe on a level surface, engage the parking brake, and chock the wheels. Raise the rear of the vehicle securely using jack stands.
2. Fuel Tank Access: Locate the fuel tank access panel (usually under the rear passenger seat or in the bed of the truck, depending on the Tahoe model). Remove the access panel.
3. Disconnect Fuel Lines: Carefully disconnect the fuel lines. You'll likely need to relieve pressure in the fuel system (consult your repair manual for specific instructions). Use appropriate fuel-line disconnect tools to prevent damage. Have rags ready to absorb any spilled fuel.
4. Disconnect Electrical Connectors: Disconnect the electrical connectors from the fuel pump assembly.
5. Remove Fuel Pump Assembly: This is often the most challenging step. You may need to use a fuel pump removal tool to carefully access and remove the assembly from the fuel tank. The assembly is usually held in place by a retaining ring or clamp.
6. Inspect and Clean: Once removed, inspect the fuel tank for any debris or damage. Clean the tank if necessary.
7. Install New Fuel Pump Assembly: Carefully install the new fuel pump assembly, ensuring it's seated correctly. Reattach the retaining ring or clamp securely.
8. Reconnect Electrical Connectors and Fuel Lines: Carefully reconnect the electrical connectors and fuel lines. Double-check all connections for tightness and proper seating.
9. Lower Vehicle and Test: Lower the vehicle and reconnect the negative battery cable. Start the engine and check for leaks. Test drive the vehicle to ensure proper fuel delivery.
Important Considerations:
* Fuel Pressure: Consult your repair manual for proper procedures for relieving fuel pressure before disconnecting fuel lines.
* Fuel Tank Evaporation: Fuel tank vapors are flammable. Work in a well-ventilated area.
* Grounding: Ensure proper grounding to prevent static electricity discharge.
* Repair Manual: A repair manual is essential. It will provide detailed, step-by-step instructions specific to your 2004 Chevy Tahoe's engine and model.
This is a complex repair. If you are not comfortable performing this repair yourself, take your Tahoe to a qualified mechanic. Improper repair can lead to serious safety hazards.
