The C and K nomenclature began for all Chevrolet pickup trucks in the 1962 model year, with the release of the C10, C15, C20, C30, K10, K15 and K20. The meaning of the letter was simple, the C meant the truck was a two-wheel-drive model and the K indicated a four-wheel-drive model. In 1996, 34 years after its introduction, the C and K naming system remained, with the Silverado being the top trim level in each version of the pickup. The 1996 C1500 Silverado came standard with a 200-horsepower, 4.3-liter V-6 engine. An electronic, fuel tank-mounted fuel pump fed fuel through the lines to the engine. Replacing this electric fuel pump requires lowering the tank and removing the fuel sending unit.
Instructions
Removal
- 1
Install a memory saver onto the vehicle, following the memory savers instructions. Loosen the negative battery cable with a combination wrench and pull the negative cable from the battery.
2Unscrew the gas cap. Find the fuel pressure service port on the fuel supply line under the hood. Insert a small flat-head screwdriver into the service port until it makes contact with the pin inside the port. Wrap the port and screwdriver in a thick shop cloth and press the screwdriver into the port to release the fuel pressure.
3Insert a fuel siphon into the fuel filler neck and place the siphons drain hose in a 5-gallon fuel can. Pump the siphon to start the flow of fuel from the tank. If the fuel can fills up, release the siphons vacuum and place its drain hose in a new 5-gallon can, then continue siphoning.
4Position wheel chocks around the front wheels. Lift the rear of the Silverado with a floor jack and slide jack stands under its frame rails. Lower the truck onto the jack stands.
5Remove the bolts securing the fuel tank shield, if equipped, using a ratchet and socket. Lower the tank shield from the underside of the truck and set it aside.
6Loosen the hose clamp securing the fuel filler hose to the fuel tank, using a ratchet and socket. Pull the filler hose from the fuel tank with a slight twisting motion.
7Place a 12-inch-long 2-by-4-inch block of wood on the floor jacks jacking plate and raise the jack until it contacts the bottom of the fuel tank, but do not apply upward pressure. Remove the nuts securing the fuel tank straps to the trucks frame and remove the straps.
8Lower the floor jack slowly to bring the tank downward. Stop lowering the tank when there is just enough room to access the fuel hoses and fuel pump wiring harness. Label each of the hoses plugged into the fuel pump with masking tape and a marker in a manner that will aid you in installing them to the right inlet on the fuel pump. Unplug the fuel pumps wiring harness and detach the hoses from the fuel pump by squeezing each quick connectors plastic ears and pulling the hose from the fuel pump.
9Lower the fuel tank completely and remove it from under the Silverado. Remove the fuel pump locking ring from the tank, by rotating it counterclockwise with a fuel sending unit wrench GM part No. J 39765 and a ratchet.
10Guide the fuel sending unit out from the fuel tank, by pulling it upward. Pull the rubber seal from the top of the fuel tank. Pull the plastic hose from the top of the fuel pump, the cylindrically-shaped electrical component on the base of the sending unit. Unplug the wiring harness from the pump, then pull the pump from its retaining sleeve.
11Twist the fuel sock one direction to break it free and pull it downward to remove it from the sending unit.
Installation
- 12
Guide a new fuel pump into the sensing units retaining sleeve and plug the wiring harness into the pumps receptacle. Install the hose onto the outlet on top of the fuel pump. Press a new fuel sock upward onto the inlet on the base of the fuel sending unit.
13Set a new fuel sending unit rubber gasket around the opening on the top of the fuel tank. Slide the sending unit back into the fuel tank, so its fuel line connections face the drivers side of the fuel tank. Install the fuel sending unit locking ring and turn it clockwise with a fuel sending unit wrench and ratchet to lock it into place.
14Slide the fuel tank back under the truck, using the floor jack and 2-by-4-inch block of wood. Raise the tank just enough to connect the wiring harness and fuel lines to the fuel sending unit. Press the fuel lines into their respective inlet on the fuel sending unit. Plug the wiring harness into the sending units receptacle.
15Lift the tank the rest of the way into its bed in the underside of the truck.
16Reinstall the fuel tank-retaining straps and hand-tighten their retaining nuts. Torque the nuts to 33 foot-pounds with a torque wrench and socket. Press the filler hose onto its inlet on the fuel tank and tighten its hose clamp with a ratchet and socket.
17Lift the fuel tank shield into place, if equipped, and tighten its retaining bolts with a ratchet and socket.
18Raise the truck off the jack stands, remove the jack stands and lower it to the ground. Reconnect the negative battery cable and tighten its retaining bolt with a ratchet and socket.
19Fill the fuel tank with the gasoline in the 5-gallon cans. Tighten the gas cap.
20Turn the ignition to the On position for two seconds, then to Off for 10 seconds. Turn the ignition back to the On position and check under the truck for fuel leaks. If leaks are not present, start the truck and verify that it runs correctly.
