Here's a general outline of the process. Always consult your vehicle's repair manual for specific instructions and torque specifications. This is not a substitute for a professional repair manual. Improper installation can lead to serious injury or damage.
1. Preparation:
* Gather Tools: You'll need a socket set (including deep sockets), wrenches, screwdrivers, a fuel pump removal tool (often a specialized strap wrench or a tool that fits into the retaining ring on the pump), jack stands, jack, safety glasses, gloves, shop rags, and possibly a fuel line disconnect tool.
* Drain the Fuel Tank (Recommended): This significantly reduces the risk of spills. You can siphon the gas using a siphon pump or carefully lower the fuel level by driving the truck until nearly empty.
* Disconnect the Battery: Disconnect the negative (-) battery terminal.
2. Accessing the Fuel Pump:
* Lower the Fuel Tank: This is typically the most challenging part. You'll need to access the tank from underneath the vehicle.
* Support the Vehicle: Securely lift the truck using a jack and support it with jack stands. Never work under a vehicle supported only by a jack.
* Locate the Fuel Tank: It's usually located in the rear of the vehicle, between the frame rails.
* Remove Access Panels: Remove any access panels or shields that obstruct access to the tank. You'll likely need to remove bolts and potentially disconnect some electrical connectors.
* Disconnect the Fuel Lines: Use a fuel line disconnect tool (highly recommended) to carefully disconnect the fuel lines from the tank. Have rags ready to absorb any spilled fuel. Be extra cautious here! There will be fuel pressure, even after disconnecting the battery; allowing some time to bleed off the pressure is very important.
* Disconnect Electrical Connectors: Unplug the fuel pump electrical connector and any other connectors attached to the tank.
* Lower the Fuel Tank Straps: Carefully lower the fuel tank straps (often using bolts or clips). Some models might require tank support before fully removing straps.
3. Removing and Replacing the Fuel Pump:
* Remove the Fuel Pump Access Plate: This is usually located on the top of the fuel tank. It may be held in place by screws or a retaining ring.
* Remove the Fuel Pump: Use the fuel pump removal tool to carefully remove the fuel pump assembly from the tank. This may require some force but avoid damaging the tank. The pump is likely held in place by a retainer ring that needs to be rotated to release it.
* Inspect the Old Pump: Carefully examine the old fuel pump for signs of damage. Note how everything is installed; it may have to go back exactly how it came out.
* Install the New Fuel Pump: Carefully install the new fuel pump assembly, ensuring it's seated correctly.
* Reinstall the Fuel Pump Access Plate: Securely reinstall the fuel pump access plate.
4. Reassembly:
* Raise the Fuel Tank: Carefully raise the fuel tank back into its position.
* Reconnect the Fuel Lines: Carefully reconnect the fuel lines, ensuring they're securely attached.
* Reconnect Electrical Connectors: Reconnect all electrical connectors.
* Reconnect the Tank Straps: Securely reconnect the fuel tank straps.
* Reinstall Access Panels: Reinstall any access panels or shields removed earlier.
* Reconnect the Battery: Reconnect the negative (-) battery terminal.
* Check for Leaks: Carefully check for any fuel leaks around the fuel lines and the tank.
5. Priming the Fuel System (Important):
* After reassembly, you'll likely need to prime the fuel system. This usually involves turning the ignition key to the "on" position (without starting the engine) for several seconds, several times in a row. This allows the pump to build up pressure.
6. Test:
* Start the vehicle and check for proper operation. Listen for the fuel pump to run when the ignition is turned on (you should hear a brief hum). Check for any leaks, unusual noises, or engine problems.
Disclaimer: This is a general guide. The specific steps may vary depending on your vehicle's model and year. Incorrect installation can cause significant damage or injury. If you're not comfortable performing this repair, it's best to take your vehicle to a qualified mechanic. A repair manual specific to your 2002 Silverado 1500 5.3L is highly recommended.
