Here's a general outline. This is not a complete, step-by-step guide and should not be considered a substitute for a reputable repair manual specific to your vehicle's year and model. Consult a Haynes or Chilton manual for detailed instructions and diagrams. Variations exist between trim levels and engine types.
1. Preparation:
* Safety First: Disconnect the negative battery cable.
* Gather Tools: You'll need jack stands, a jack, socket wrench set (metric), various size wrenches, screwdrivers (Phillips and flathead), fuel line disconnect tools, safety glasses, gloves, rags, and a new fuel pump assembly (ensure it's the correct one for your engine).
* Drain Fuel Tank (Recommended but not always necessary): This significantly reduces the risk of spillage. Consult your repair manual for the best method for your vehicle.
2. Accessing the Fuel Pump:
* Locate the Fuel Pump: It's usually located inside the fuel tank, accessed from underneath the vehicle.
* Raise and Support the Vehicle: Safely jack up the rear of the Caprice and securely support it with jack stands.
* Remove the Fuel Tank Access Panel: This may be a panel under the vehicle's rear or require dropping the fuel tank itself (more common). The exact procedure depends on your model. Your repair manual will provide details and diagrams.
3. Replacing the Fuel Pump:
* Disconnect Fuel Lines: Carefully disconnect the fuel lines from the pump. Use fuel line disconnect tools to avoid damage. Have rags ready to absorb any fuel spillage. Be aware that some pressure may remain in the lines.
* Disconnect Electrical Connectors: Disconnect the electrical connector from the fuel pump.
* Remove the Fuel Pump: Depending on the access method (through an access panel or dropping the tank), you will either remove the fuel pump assembly from the access panel or remove the sending unit assembly from the tank. This often involves removing retaining clips, bolts, or nuts.
* Install the New Fuel Pump: Install the new fuel pump assembly, ensuring it's securely seated and all connections are properly made.
* Reconnect Fuel Lines and Electrical Connectors: Carefully reconnect the fuel lines and electrical connector to the new fuel pump.
* Reinstall Access Panel or Fuel Tank: Carefully re-install the fuel tank access panel or the entire fuel tank, paying close attention to securing bolts, lines and any other components removed during access.
4. Testing and Completion:
* Lower the Vehicle: Carefully lower the vehicle from the jack stands.
* Reconnect the Battery: Reconnect the negative battery cable.
* Check for Leaks: Inspect all connections for leaks.
* Start the Engine: Start the engine and check for proper fuel pressure. You may need a fuel pressure gauge to ensure proper operation. Listen for any unusual noises from the fuel pump.
Important Considerations:
* Fuel Pressure: Incorrect fuel pressure can damage your engine. Consult your repair manual for the correct fuel pressure specifications.
* Safety: Gasoline is highly flammable and potentially explosive. Work in a well-ventilated area and follow all safety precautions.
* Repair Manual: This is a general overview. A repair manual specific to your 1986 Chevy Caprice Classic is absolutely essential for detailed instructions and diagrams.
This process can be complex and requires careful attention to detail. If you're not comfortable performing this repair yourself, it's best to take your vehicle to a qualified mechanic. Improper installation can lead to serious problems, including fire.
