2002 HD Fuel Pump/Tank Removal

[Ol'Jim]

My 02 Crew Cab 4x4 Silverado apparently needs a new fuel pump.
Going to get a pressure gauge to test it, but can't hear it, so assume it is dead. Checked all fuses & relays, even swapped them with known good ones. Removed & cleaned ground wire.

Before I drop the tank, (and $280-300 on a pump), is there any way to get to the electrical connector that feeds the pump? It looks like all the wiring is above the tank, can't get to anything. I would like to try feeding 12v of fused power to the pump connector. (Or at least measure for 12v somewhere near the tank), just don't know where to get to it.

If that is not possible, how tricky is dropping the tank? Lucky for me, it is only 1/4 full. Have already hit the strap bolts with rust buster. I know the filler tube needs unbolting at fuel door, and the tank straps. Anything else?
Will the lines allow me to drop the tank, or do I need to get a tool to disconnect them first?
Any other issues to look out for?
Thanks, -Jim.

[j cAT]

Originally Posted by Ol'Jim

My 02 Crew Cab 4x4 Silverado apparently needs a new fuel pump.
Going to get a pressure gauge to test it, but can't hear it, so assume it is dead. Checked all fuses & relays, even swapped them with known good ones. Removed & cleaned ground wire.

Before I drop the tank, (and $280-300 on a pump), is there any way to get to the electrical connector that feeds the pump? It looks like all the wiring is above the tank, can't get to anything. I would like to try feeding 12v of fused power to the pump connector. (Or at least measure for 12v somewhere near the tank), just don't know where to get to it.

If that is not possible, how tricky is dropping the tank? Lucky for me, it is only 1/4 full. Have already hit the strap bolts with rust buster. I know the filler tube needs unbolting at fuel door, and the tank straps. Anything else?
Will the lines allow me to drop the tank, or do I need to get a tool to disconnect them first?
Any other issues to look out for?
Thanks, -Jim.

unbolt the bed and you can slide back a foot and lift at an angle to get at the connections to the pump.

or block up bottom of tank remove straps and jack up body to get at the connections for testing or removal of the pump.

straps/vapor fuel lines/ground strap/electrical connectors/and the fuel filler hose at the filler door.

[Ol'Jim]

Thanks j cAT,
Pressure at fuel rail ranged from 0-10 PSI, (tested 8x). So I am fairly certain pump is getting power, and is shot. I have put 97,000 miles on her, truck has 194K on it, and may even have original pump in it. Glad it died just around the corner from home!

Autozone has the Airtex pump for $255, and can order the GM (AC/Delco) unit for $305, with overnight delivery to the local store. Based on comments I have read on this and other sites, I think I will spend the extra $50 and (hopefully) not have to replace the thing for years. Both have 1 year warranty.
Anyone know of better pricing for the GM pump Assy?
Thanks again,
-Jim.

[j cAT]

Originally Posted by Ol'Jim

Thanks j cAT,
Pressure at fuel rail ranged from 0-10 PSI, (tested 8x). So I am fairly certain pump is getting power, and is shot. I have put 97,000 miles on her, truck has 194K on it, and may even have original pump in it. Glad it died just around the corner from home!

Autozone has the Airtex pump for $255, and can order the GM (AC/Delco) unit for $305, with overnight delivery to the local store. Based on comments I have read on this and other sites, I think I will spend the extra $50 and (hopefully) not have to replace the thing for years. Both have 1 year warranty.
Anyone know of better pricing for the GM pump Assy?
Thanks again,
-Jim.

if your pump is the original this would be when they fail with proper fuel levels and filter replacement . usually the pressure with the pump running shows around 40-50 psi when issues begin. having 10 psi is odd with the pump still running.after you replace the pump check the fuel pressures and change the filter.2002 still had the filter. newer vehicles GM made this part of the pump assy.

most here have found the delphi fuel pumps are the best performance/life. pricing changes so internet searching is needed.

airtex is not recommended .many here reported failures after a few months.

[777stickman]

You'll need to give them the full VIN via their e-mail.

http://www.gmpartsdirect.com/

[Ol'Jim]

Just wanted to follow up on this one. Verified pump failure, electrical signal was correct at connector, proper 2 second "pulse" when turning on ignition.

Autozone was a nightmare, special ordered the Delphi pump, (all they stock is Airtex). Paid $335 cash on a Monday, they promised it by Wednesday, but still didn't have it on Saturday. Got my $$ back, went to Napa, they had it in stock, but it cost $356. Installed it, and it is back to running perfectly.
Glad I went with the advice I received to remove the bed, turned out to be very easy. Hit the threads on all 8 bolts with some PB Blaster an hour before I removed them, and they came out easily. 3 friends and I lifted it up and moved it back. There was a lot of silt & dried mud/dirt around the top of the tank/pump, which would have been difficult to remove if I had chosen to drop the tank. I was able to use my blow gun and get it cleaned off before removing the pump. Was surprised how clean the tank was inside.
Thank you guys for the great information and advice, as always!!
-Jim.

[j cAT]

Originally Posted by Ol'Jim

Just wanted to follow up on this one. Verified pump failure, electrical signal was correct at connector, proper 2 second "pulse" when turning on ignition.

Autozone was a nightmare, special ordered the Delphi pump, (all they stock is Airtex). Paid $335 cash on a Monday, they promised it by Wednesday, but still didn't have it on Saturday. Got my $$ back, went to Napa, they had it in stock, but it cost $356. Installed it, and it is back to running perfectly.
Glad I went with the advice I received to remove the bed, turned out to be very easy. Hit the threads on all 8 bolts with some PB Blaster an hour before I removed them, and they came out easily. 3 friends and I lifted it up and moved it back. There was a lot of silt & dried mud/dirt around the top of the tank/pump, which would have been difficult to remove if I had chosen to drop the tank. I was able to use my blow gun and get it cleaned off before removing the pump. Was surprised how clean the tank was inside.
Thank you guys for the great information and advice, as always!!
-Jim.

good luck with the vehicle. keep it as long as you can these new GM trucks look great , but come with many MAJOR issues...