Before You Begin:
1. Safety First: Disconnect the negative battery cable. This prevents accidental sparks. Work in a well-ventilated area away from ignition sources.
2. Gather Tools: You'll need a jack, jack stands, wheel chocks, socket set (metric), wrenches, fuel line disconnect tools, a fuel pump pliers (highly recommended), safety glasses, gloves, rags, and possibly a fuel pump pressure gauge (to verify the new pump's function afterward). A shop manual specific to your year and model Suburban is invaluable.
3. Obtain Replacement Parts: Get a new fuel pump assembly (it usually comes with a sending unit and filter). It's also a good idea to replace the fuel filter while you're at it.
4. Prepare: Drain some fuel from the tank to reduce pressure and the amount of fuel you'll be working around. You can do this by carefully removing the fuel cap and letting some fuel out.
Steps (General Outline - Consult a Repair Manual for Specific Details):
1. Vehicle Preparation: Secure the vehicle on jack stands after safely raising it. Chock the wheels.
2. Access the Fuel Pump: This usually involves lowering the fuel tank. This requires disconnecting various components:
* Fuel Lines: Carefully disconnect the fuel supply and return lines. Use fuel line disconnect tools to avoid damaging the lines. Have rags ready to absorb any spilled fuel. Some recommend plugging the lines to prevent fuel loss and air entry.
* Electrical Connectors: Disconnect the fuel pump electrical connector.
* Tank Straps/Hold-downs: Loosen and remove the straps or bolts holding the fuel tank in place.
* Fuel Tank: Carefully lower the fuel tank. This might require support from a helper. The tank is often heavy and contains fuel.
3. Fuel Pump Removal: Once the tank is lowered enough, you'll usually find access to the fuel pump assembly at the top of the tank. This may require removing a retaining ring or cover.
4. Pump Replacement: Remove the old fuel pump assembly. Carefully compare the old and new assemblies to ensure correct installation. Pay close attention to any gaskets or seals.
5. Pump Installation: Install the new fuel pump assembly, ensuring everything is correctly seated.
6. Reassembly: Raise the fuel tank back into place. Reconnect the fuel lines, electrical connectors, and straps. Double-check all connections before proceeding.
7. Testing: Lower the vehicle. Reconnect the battery. Check for leaks. Start the engine and verify that there's no fuel leak and the engine runs smoothly. You may want to use a fuel pressure gauge to check fuel pressure.
Important Notes:
* Fuel Tank Lowering: This step varies significantly between vehicles. Your Suburban's specific procedure will be crucial and needs to be sourced from a repair manual.
* Safety: This is crucial throughout the entire process. Fuel is highly flammable. Avoid sparks and open flames. Work in a well-ventilated area.
* Repair Manual: A Haynes or Chilton repair manual specific to your 1997 Chevy Suburban 1500 is highly recommended. It will have detailed diagrams and instructions, making the job significantly easier and safer.
This is a general overview. Attempting this repair without experience and a repair manual is strongly discouraged. If you're uncomfortable performing this repair, it's best to take your Suburban to a qualified mechanic. The risk of fire or injury outweighs the cost of professional service.
