🔧 Fuel Pump - Replacement

Your Sierra uses an in-tank fuel pump module, so the fuel tank must be lowered to replace it. This is a bigger job, but it is very doable at home with safe lifting support and the right tools.

Difficulty Level: Intermediate | Estimated Time: 3-5 hours

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⚠️ Safety & Precautions

• Work outside or in a very well-ventilated area. Fuel vapors are flammable.
• No smoking, sparks, hot lights, or open flames near the truck.
• Relieve fuel pressure before opening any fuel lines.
• Disconnect the negative battery cable before starting.
• Use a transmission jack or floor jack with a wide support pad to lower the fuel tank safely.
• Do not let the tank hang by the filler neck or wiring.
• If your truck has a lot of fuel, drain or run it low first. A full tank is heavy and unsafe to lower.

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🔧 Required Tools

You'll need the following tools for this repair:

• Fuel line quick-disconnect tool set
• Ratchet
• 8mm socket
• 10mm socket
• 13mm socket
• 15mm socket
• Torque wrench
• Floor jack rated 3-ton minimum
• Jack stands rated for truck weight
• Wood block
• Fuel-safe drain pan
• Trim removal tool
• Brass punch
• Hammer
• Safety glasses
• Nitrile gloves

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Fuel pump module - Qty: 1
• Fuel pump module seal - Qty: 1
• Fuel tank strap bolts - Qty: 2
• Fuel line O-rings - Qty: 1 set
• Fuel filter - Qty: 1
• Fuel pump relay - Qty: 1
• Fuel injector/fuel system cleaner - Qty: 1

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📋 Before You Begin

• Park on level ground and set the parking brake.
• Run the fuel level low if possible. Less fuel makes this much safer.
• Disconnect the negative battery cable before touching the fuel system.
• Relieve fuel pressure at the fuel rail service port before disconnecting lines.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Relieve fuel pressure and disconnect power

• Use the fuel line quick-disconnect tool set and a safe container to bleed off fuel pressure carefully at the service connection.
• Disconnect the negative battery cable using a 10mm socket.
• Keep a rag ready for small fuel spills.

Step 2: Raise and support the truck

• Use the floor jack to lift the truck.
• Place it securely on jack stands.
• Make sure the rear of the truck is stable before going underneath.

Step 3: Lower the fuel tank enough to access the module

• Use a 15mm socket to remove the fuel tank strap bolts.
• Support the tank with the floor jack and a wood block.
• Lower the tank slowly.
• Disconnect the filler neck, vent hose, EVAP lines, and fuel pump connector as they become accessible.
• Torque to 40 Nm (30 ft-lbs) on installation for the fuel tank strap bolts.

Step 4: Remove the fuel pump module

• Clean the top of the tank first so dirt does not fall inside.
• Use a brass punch and hammer to carefully loosen the lock ring.
• Lift the fuel pump module straight out of the tank.
• Remove the old seal and clean the sealing surface.
• Do not use steel tools on the tank flange.

Step 5: Install the new fuel pump module

• Install the new fuel pump module seal on the tank.
• Lower the new fuel pump module into place in the same orientation as the old one.
• Install and tighten the lock ring securely with the brass punch and hammer until fully seated.
• Reconnect the electrical connector and fuel lines.
• Check that the seal stays in its groove.

Step 6: Raise the tank and reconnect everything

• Use the floor jack to raise the tank back into position.
• Reconnect the filler neck, vent hose, EVAP lines, and fuel pump connector.
• Install the tank strap bolts with the 15mm socket.
• Torque to 40 Nm (30 ft-lbs).

Step 7: Reconnect power and prime the system

• Reconnect the negative battery cable with a 10mm socket.
• Turn the key to ON for 2-3 seconds, then OFF.
• Repeat this 3 times to prime the fuel system.
• Check carefully for fuel leaks at the tank and lines.

Step 8: Start and verify operation

• Start the engine using the ignition key.
• Let it idle and inspect again for leaks.
• Confirm normal fuel pressure and smooth running.

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✅ After Repair

• Inspect the tank area one more time after a short test drive.
• Recheck for fuel smell or any wet spots under the truck.
• If the engine cranks long or stalls, cycle the key again to re-prime the system.
• If a check engine light stays on, scan for fuel system codes.

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💰 DIY vs Shop Cost

Shop Cost: $900-$1,600 (parts + labor)

DIY Cost: $250-$550 (parts only)

You Save: $650-$1,050 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 3-5 hours.

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🎯 Ready to get started?

HowToo makes it easy: same-day/2-day shipping on every part, plus all the tools and specialty tools you need! Check out the parts and tools sections below to add everything to your cart.