Safety First:
* Work in a well-ventilated area. Gasoline fumes are extremely flammable and dangerous.
* Wear safety glasses.
* Have a fire extinguisher readily available.
* Use proper jack stands. Never work under a vehicle supported only by a jack.
* Dispose of fuel properly. Do not pour gasoline on the ground.
Tools You'll Need:
* Jack and jack stands
* Socket set (metric)
* Wrenches (metric)
* Screwdrivers (Phillips and flathead)
* Fuel line disconnect tool (or pliers – use caution)
* Fuel pump pliers (optional, but helpful)
* Torque wrench (highly recommended)
* Shop rags or absorbent material
* Safety glasses
* Gloves
* Fuel pressure gauge (to test after installation)
* New fuel pump assembly (with the correct specifications for your Suburban's engine)
* Possibly a new fuel filter
Procedure:
1. Disconnect the Battery: Disconnect the negative battery terminal.
2. Lower the Fuel Tank: This is usually the most challenging part. The method varies depending on the specific Suburban model (1500, 2500, etc.). Consult a repair manual specific to your year and model. Generally, it involves:
* Accessing the fuel tank straps from underneath the vehicle.
* Carefully lowering the tank using a jack or hoist. Be extra careful not to damage the fuel lines or the tank itself.
* Supporting the tank as you lower it, using jack stands or other secure support.
3. Disconnect Fuel Lines and Electrical Connector: Once the tank is lowered enough, you can access the fuel pump.
* Carefully disconnect the fuel lines. Use caution to prevent fuel spillage. A fuel line disconnect tool is highly recommended. Clamp off the lines after disconnecting to prevent fuel loss.
* Disconnect the electrical connector to the fuel pump.
4. Remove the Fuel Pump Access Plate: This is usually a cover on top of the fuel tank. It may be secured by screws or clips. Remove this carefully.
5. Remove the Fuel Pump: The fuel pump is often held in place by a retaining ring. This is where fuel pump pliers are beneficial. Carefully remove the retaining ring and then lift out the fuel pump assembly.
6. Inspect the Fuel Pump and Tank: Inspect the fuel tank for any damage or debris. Check the fuel sending unit (if part of the assembly) while you have access.
7. Install the New Fuel Pump:
* Reverse the removal process to install the new fuel pump assembly. Make sure the o-rings are properly seated.
* Securely attach the electrical connector.
* Connect the fuel lines firmly, ensuring there are no leaks.
8. Raise the Fuel Tank: Carefully raise the fuel tank back into place and secure it with the straps.
9. Reconnect the Battery: Reconnect the negative battery terminal.
10. Prime the Fuel System: Turn the ignition key to the "on" position several times (don't crank the engine) to prime the fuel pump and system. You may hear the pump whirring.
11. Check for Leaks: Carefully inspect all fuel line connections for leaks.
12. Start the Engine: Start the engine and let it run for a few minutes. Check for any leaks or unusual noises.
13. Test Fuel Pressure: Use a fuel pressure gauge to test the fuel pressure to ensure it is within specifications (consult your repair manual).
Important Notes:
* Repair Manual: A repair manual specific to your 1996 Chevy Suburban is highly recommended. It will provide detailed diagrams and instructions specific to your vehicle's make and model, significantly reducing the risk of errors and damage.
* Professional Help: If you are not comfortable performing this repair yourself, it's best to take your Suburban to a qualified mechanic. This is not a simple task and incorrect installation can lead to serious problems.
This is a general outline. The specific steps may vary slightly depending on your Suburban's exact model. Always consult a repair manual for detailed, accurate instructions for your particular vehicle. Remember, safety is paramount when working with fuel.
