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Posted on Oct 25, 2009
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Replace fuel pump for 2002 gmc sierra 2500 - 2002 GMC Sierra 1500

1 Answer

Greg Bernett

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  • GMC Master 2,993 Answers
  • Posted on Oct 25, 2009
Greg Bernett
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Joined: Mar 04, 2009
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First...this is where the pump is (gas tank) on the engines listed:

replace fuel pump for 2002 gmc sierra 2500 - 6f9f9d7.gif

Illustrating fuel pump and sending unit sensor (3) on 1999-2005 4.8L, 5.3L, 6.0L Engines


Removal & Installation

  1. Before servicing the vehicle, refer to the Precautions section.
  2. Remove or disconnect the following:
    • Negative battery cable
  3. Relieve the fuel system pressure.
  4. Drain the fuel tank.
  5. Remove or disconnect the following:
    • Fuel tank
replace fuel pump for 2002 gmc sierra 2500 - 8e4564e.gif/uploads/images/8e4564e.gif" alt="8e4564e.gif" class="h_mi" />
WARNING Do not handle the fuel sender assembly by the fuel pipes. The amount of leverage generated by handling the fuel pipes could damage the joints.

  • Fuel sender assembly retaining ring using a fuel tank sending unit wrench. Remove the fuel sender assembly and the seal. Discard the seal.
  • Note the position of the fuel strainer on the fuel sender. Support the fuel sender assembly with one hand and grasp the strainer with the other hand. Pull the strainer off the fuel sender. Discard the strainer after inspection. Inspect the strainer. Replace a contaminated strainer and clean the fuel tank.
    • Fuel pump electrical connector
    • Electrical connector retaining clip from the fuel level sensor
    • Sensor electrical connector from under the fuel sender cover
    • Fuel level sensor retaining clip
  • Squeeze the locking tangs and remove the fuel level sensor.
  • Remove the fuel pressure sensor.
  • To install:
    1. Install or connect the following:
      • Fuel pressure sensor
      • Fuel level sensor
      • Sensor retaining clip
      • Electrical connector to the fuel level sensor
      • Electrical connector retaining clip to the fuel level sensor
      • Fuel pump electrical connector
      NOTE Always install a new fuel strainer when replacing the fuel tank fuel pump module.

      • New fuel strainer in the same position as noted during disassembly. Push the strainer on the bottom of the fuel sender until the strainer is fully seated.
      • New seal on the fuel tank
      NOTE The fuel pump strainer must be in a horizontal position when the fuel sender is installed in the tank. When installing the fuel sender assembly, assure that the fuel pump strainer does not block full travel of the float arm.

      • Fuel sender assembly into the fuel tank
      • Fuel sender assembly retaining ring
      • Fuel tank. Install the fuel tank strap attaching bolts. Tighten the bolts to 30 ft. lbs. (40 Nm).
    2. Refill the fuel tank. Install the fuel filler cap. Connect the negative battery cable.
    3. Turn the ignition ON for 2 seconds.
    4. Turn the ignition OFF for 10 seconds.
    5. Turn the ignition ON.
    6. Inspect for fuel leaks

    4 Related Answers

    Anonymous

    • 191 Answers
    • Posted on Mar 14, 2010

    SOURCE: REPLACE FUEL PUMP GMC 2002 SIERRa

    the pump is in the gas tank siphon the gas out and remove the straps holding the tank(you will also need to remove the three screws holding the filler neck to the truck box under the filler door.)as you drop the tank you will also need to unplug the wiring to the top of the tank and the fuel lines they are usually plastic clips,but if this has been done before and the clips got broken from the first time they could have put clamps in place of the clips.I have found it much faster to remove the truck box itself and that way you don't have to drain the tank and it stays stationary while you RandR the pump with less chance of breaking anything.
    Also did you double check the fuel pump relay under the hood in the relay box,I would start there first.
    Hope this helps good luck.

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    toddmat

    • 44 Answers
    • Posted on Jun 08, 2010

    SOURCE: replaceing fuel pump on gmc sierra

    The fuel pump is located INSIDE the gas tank and is a combination fuel pump/sending unit for the fuel gauge. Be prepared for a large repair bill. About $600!

    Ironfist109

    Iron

    • 3018 Answers
    • Posted on Sep 04, 2011

    SOURCE: 03 gmc sierra 2500 hd

    • Can you tell me how you tested the fuel pressure and what was the fuel pressure with the truck running? and when you shut your truck off? What size engine? Flex Fuel? Turbo Diesel? Gasoline?

    • Your fuel filter hold the fuel pressure every bit as much as the back pressure valve in the pump does. I recommend changing this as well. Cheap and easy fix and every bit as necessary.

    • Your fuel filter should be located on the undercarriage along the drivers side rail. It will require a gas line tool to get the line off. If it is not the it is the engine compartment and much more caution should be used. Change with the engine cooled down.

    • If you have any comments please feel free to leave them here and I will respond to you.
    • Hope this helps and thank you for using FixYa.

    Regards, Tony

    Anonymous

    • 1486 Answers
    • Posted on Aug 01, 2009

    SOURCE: 2002 gmc sierra wont start without useing jumper

    Yes it has a rubber cover over it in the engine compartment.i would change the relay.good luck.

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    the pump is in the gas tank siphon the gas out and remove the straps holding the tank(you will also need to remove the three screws holding the filler neck to the truck box under the filler door.)as you drop the tank you will also need to unplug the wiring to the top of the tank and the fuel lines they are usually plastic clips,but if this has been done before and the clips got broken from the first time they could have put clamps in place of the clips.I have found it much faster to remove the truck box itself and that way you don't have to drain the tank and it stays stationary while you RandR the pump with less chance of breaking anything.
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