Fuel Pump Replacement: Chevy GM Truck 

The wires are a different gauge to carry more current, that's why the harness is updated.

Ivan does a great job always but stumbled a bit on this one. Nice idea to try to keep the original pump connector (square one), BUT it was changed to the flat one with bigger pins to correct the old square plug which can overheat and melt. Be sure to just upgrade the truck harness with the new flat plug that is suppled with new pump, and keep the new pump as it comes. The giveaway was the larger pins in the new flat plug. No problem, Ivan, you are still batting nearly 1,000!

i know you posted this a while ago. i replaced the pump and still couldn't get the engine to run, scratch my head a bit, scoured youtube for guidance, then final at the end of your video was my solution.. the ground wire for the pump and the ground for the filler were not properly grounded.. thanks dude.

Going on 18 years as a GM technician and the pig tail that comes with the new pump should be replaced GM update the harness because of premature pump failure the repair you just preformed looks more time consuming then just installing the harness that came with the pump it was still a goo video thumbs up

Had to do this to my ol Chevrolet. I used the Delphi unit as well. I did do the swap on the harness and installed the new one. All new pumps come with the new style connector. If done correctly, those harness crimps seal Nicole's, as they are heat shrink, and for added security, put some heat shrink over it. I find that's the best way to do it. I think Chevy had a problem with the square connector, if I remember from my research. Anyways good video.

The updated harness is required. You will void warranty if not used. Just do the complete repair. No shortcuts.

'Big Nasty" would have sent that sender into orbit!

That's the correct Delphi unit for that truck. GM superseded the original design with the updated design you have there. Even the dealership techs have to deal with the whole cut-and-splice garbage. :(

ahh always a fun job especially in PA! nice job Ivan.

I see myself saying come on lil fella alot more after watching Eric O videos now . Great video

Nice diagnosis Ivan from the previous video and great work on the fuel pump replacement. I'm like you in why didn't a Delphi pump have the electrical connectors on it like the original. I would done the same thing as you in swapping over the old connectors to the new assembly. I mean who likes to bastardize work by cutting factory wires and then splicing. And it would have been nice if the manufacturer could have provided the plastic fuel and evap line connectors. On the fuel pump waveform, it did look a little raggy and didn't have a typical 'sawtooth' look to it. You'll find that after a few hours of running that the waveform should clean up a little bit when the brushes get fully seated. Nice work as always!

Very informative... might have been good idea to see why the older one was acting the way it was... good job of making it work

Enjoy your videos however Fuel pumps are expensive if something goes wrong when swapping the plugs... The last FP I changed I spliced on the new plug in minutes no big deal.

Nice you learn something new everyday good job on this fuel pump install

yeah...the wire swap was a lot of extra work all to void the warranty and increases the chance of future problems....the update was a necessary mod

The new plug is sent with the pump as there were problems with connections and some would melt. Seen many pumps replaced and all that wrong was the pigtail. You may do as you like but its faster to pull the bed off than to drop the tank. 4 bolts ,unplug taillights and remove filler neck hose. Pick up bed and sit on tires. Takes about an hour.....Shortcuts such as the plug and not replacing the Fuel filter do your customer a disservice and will always bite you in the butt. I spent 30+ years in auto parts sales and repair and there is a reason manufacturers send new plugs and lock rings etc is to prevent comebacks ,

they make a real nice tool for removing that ring

Updated harness connector should have come in the box . Mine did . I put a carter pump in mine , great for the last 3-4 years. Ugly looking wave form compared to what you see as a good after it's been run for a while. Love the rust :)

I always change the harness. I figure if they made the change it was for a reason. It might be because it's the same pump for a newer model. That way there is only one part number. Great job anyway, Ivan.

Yep, that updated plug was in the kit for a reason, i have personally seen a handful of them melted. I bought a 2000 Blazer in really nice shape a few years ago because the guy had done exactly what you just did, swapping plugs and harnesses instead of snipping 4 wires, in this case, the plug on the pump pigtail melted at the passthru inside the tank after he drove it for a day, he thought is was another NEW problem and got pissed and dumped it cheap, i snagged it for $500 bucks 98,000 miles, zero rust, very nice shape, he left the box from the delphi the pump in the back, i diagnosed it quickly as no current on the pump circuit, dropped the tank, restored the swapped connectors and installed that pigtail and it was fixed for free. You even noticed that the connectors had larger pins, the reason for the update was because of the connections in the square connector loosening over time, the larger pins in that flat connector made more surface contact and thus could handle more current without producing heat. Less heating, less metal fatigue in the pins, the longer they hold a tight connection, as soon as they loosen up in that square connector they will overheat and melt it. Look up GM TSB #04-06-04-088C Good Job putting in a Delphi, but in my opinion, not changing that plug was risky business.

The last FP I did was on a Chevy Cavalier. Only the whole sending unit was available as FRU (Field Replaceable Unit) -- aftermarket $200, OEM $325. Uh, no... I did some research and found a vendor on eBay selling just the ACDelco pumps new for less than $50.00. So, I did the work and swapped out just the pump in the old sending unit. The Internet is a godsend to those of us financial efficiency experts.

That's the way to do it. I wish I would have thought of that because I had to change my trucks harness and it's never worked as well since. (The fuel gauge bounces around). Great job on the rig!

You are a more meticulous man than I am. There is no way I'd have faffed swapping connectors on the pump. I'd have used the bodge wiring connectors and shipped it out!

Its an updated connector, those early style 2000's gm were known for melting the connectors, even gm fuel pumps come like that.

Another interesting video, Thanks. But don't you run the risk of connecting the pump backwards in the connector and then running the pump in reverse. I would mark the pump wires so you maintain the correct orientation in the plug.

I always oil any kind of push/clip on hose connectors before re fitting. It helps the O rings to slide on and seat without twisting them. Plus I feel that a smear of oil on the big seal would have helped that clamp ring to seat down

Appologize for... we all have a right to express ourselves, but we also should except people for who they are... can't change them only ourselves and influence young ones to guide them in right direction

Hey Ivan, nice repair, and nice music too

It was like you were working on the star ship Enterprise.. Hope you get the joke . Job well done.. Cheers.

the connector that you did not replacement was for poor connections that develop over time. that was a update that GM made so we replace them every time a truck had fuel issues.

The internal screen is a bad "improvement" in my opinion. I've never changed the fuel pump plug like that, my understanding and experience is the original wiring plugs can corrode or melt, hence the "upgraded" plug and pigtail. A nuisance and a potential failure point if you don't solder and use a good quality heatshrink. Not a issue as long as the original plug is in good condition.

Ivan I would say they dont include the lock-ring as part of the pump kit because..in states like Washington ..we dont get rust like that ,,MAYBE after 30 years

Great video. Chevy trucks. The best invention in the history of mankind,,,, second only to Ice Lollies LOL!!!!!

Remember P B Blaster is your friend ! :-) God bless Wyr

really like your attention to detail on the repining of the harness. I hate cutting and but connectors when not needed; although judging by the look of the truck, the owner will not even care. I wish I had repined the harness when i replaced the blower control module on my 06 Sierra. The truck is perfect with only 65K miles. After i cut the wire i said to myself, "you dumb ass, why didn't you simply change the plugs around!"

Acdelco version has new plug also

good work Ivan thank you for your video have a good day GS out

Good idea i don't like cutting any wires also thanks for the info.

So I’m doing this myself and my middle return line on the pump had no clip. Was just curious if you can remember if that like had a clip or if it just plugged on the pump. Thank you

You should give it little heat with the torch in that rusty collar Ring 😂

Great AC-DC song playing...

hey gm has and had ground problems thats why gave you a new harness to replace if that new connector isn't replaced you will always have pump problems

Good job

Neatly done, sir.

great video bud the connector was updated due to terminal issues I believe there is a tsb on this

I know this video is old bit the connector was upgraded for replacement pumps, I did it on my s10 and lesabre it's no big deal to change it.

No ground, made the exact same error on my Astro this summer.

The 2 purple wires you installed are they polarity sensitive???

Are the butt connectors weather proof, or just plain junk ? would soldering, and quality sealing heat shrink be a way to go? ... just things to consider. Maybe you could do a video on connecting wiring? I think your followers learn a lot from you, I know I have.

What if the two purple wires are on backwards ...will the fuel gauge ready empty when it's full ??

I give you a lot of credit.... I try not to touch fuel tanks. Too much risk and you end up stinking of raw fuel. I was doing a fuel pressure check on a F150 with the quick connect fuel lines and the whole place stunk of fuel I had tone go out and get fresh air

Ivan, I didn't see you observe polarity on the purple sending unit wires. Did you just get lucky, or does the fuel gauge simple respond to the increase or decrease in resistance across the purple wires?

You need to buy the strainer sock separately

Nice work! Duuddee this camera battery though!

The wire harness is like that because the old one's burned up when the pin's got rusty.

shoot .. I would love to watch this,, but got to leave for work early ..we got 1/32 of an inch of snow here in Seattle ..and it will slow up everything LOL

Hi Ivan just replayed the waveform of the new pump. Was I imagining things or did that waveform look a big ordinary. You didn't comment but do you agree its looked a bit sad out of the box?

Good video as usual. Does changing the wiring to the old plug affect the warrantee on the new pump? Also I normally add a little oil or white grease to the o rings and tank seal. I am surprised that the pump did not come with the fuel line clips on the new pump. Boy are things getting cheap in the parts industry. Keep up the good video's.

What brand coupler you using for your air hose? ADP Training has a video on RU-vid of using that sensor to make a homemade pressure transducer.

why do you skip over video of tank removal? I would like to see the whole operation for better or worse!

All the new GM pumps come with new plugs. The old plugs had a tendency to melt and catch fire that's why they were switching plugs.

Hey Ivan! Interested issues I've been having. Wanted to get your thoughts. My next step is to see if my buddy can look on All Data. 1997 Chevy Blazer 4.3, 2 door, auto, 4x4. issue is the gauge isn't reading accurately once it gets down to 8 or 9 gallons of gas in the tank. The tank is a 19 gallon and it is in the very back because it's a 2-door model. After driving for more than a half hour the gauge will sneak it's way down to almost empty and sit there. Once I shut off and restart the Blazer the gauge will start reading closer to where it should be but is still off (lower) by about 1/8 of a tank. I also noticed when I first turn the key to the ON position but, not actually start the engine the fuel gauge will spike all the way past the full mark super fast then drop down towards a more actuate reading. It never did this until last night. Finally I am also getting gauge fluctuation when I step on the brake pedal, turn off or on any lights or accerories. The fuel gauge will move it bit and return to it's current location. Back 3 years ago I replaced the fuel pump and sending unit in the tank along with the 4-pin wire harness connecter. It seemed to correct this issue with the gauge not reading correctly and drifting to empty when I still had almost a half of a tank. Now the problem is back! I soldiered and heat shrunk the new connector for the fuel pump/sending unit to the main harness to prevent connection issues. I also used and AC-Delco pump/sending unit. To be honest this issues has gotten old. I was wondering if you have any thoughts? I also wanted to mention that I did some research and a few people online mentioned a "Fuel Gauge Buffer Module" under the glove box that is present in 1997 models and could be an issues. Also when you turn on headlights, step on brake, use turn signals or do anything that puts a load on charging system the fuel gauge jumps a little. Thanks for reading!

Is this fuel tank plastic or metal?

Lord, that fuel sock looks totally slugged up with garbage. That will kill off a fuel pump wicked quick! Wonder how much (as I'm only part way through the video) Wondering how much trash is sitting in the bottom of that tank!

Ivan, I think you got lucky on the purple wires. Did the fuel gauge read accurately after you got the truck started?. It's a good idea to transfer the pins one at a a time from plug to plug otherwise its possible to reverse their positions so that he fuel meter reads 'full' when it is empty and vice versa.

How much do you charge for labor

WHAT A PLIVIT!! (10 POUNDS OD CRAP IN A 5 POUND BAG:"

They have changed the connector style not because the new design is safer or so they only changed it because its not made by GM original equipment manufacturer anymore so long for the great heritage of made in USA

Geez, Louise, man... I'd have used the parts included in the kit and adapted the truck harness to the new pump assembly... Lots less work.

last one I did was like that with the connectors

I saw something said airtex in the box. Guess you can't get a real oem model anymore then. Might as well go to advance I guess

one question is this tank from a v8 motor

So after manufacturer sees this they can only send the parts that you used and safe even more money.

What's the best penetrating fluid? Does atf and acetone actually work better than pb blaster?

Filler neck died on my '98 E150 after 16 years.

That harness kit they send you is a joke. How long do they think a mickey mouse solder and crimp is going to last in the PA salt and corrosion extravaganza? Looks like that filler neck breaking just saved the guy a diagnosis for an EVAP code a few months down the line as well!

Nice !

Hey Ivan got one for ya. Fuel related. Guy I know has new Dodge Truck. No matter what he can't get it to fill up over 3/4 tank on the fuel gauge. What's the problem? answer later today if you or no one figures it out. True story btw.

Ivan, can I ask why you changed the whole module & not just the Fuel Pump?

wow that filler neck and lock ring should be stainless...

hmmm genuine.. reminds me of that blower motor resistor lol

We didn't see it run

The video about just being black, very powerful message... It sounds like we want to stand alone,we the world help build all brands... video previously about being falsely pictured... Not sure it is totally true... Rap,gang,clubs,groups paint these pictures,videos,jail,prison, attitudes and the image we want to send... change begins with ourselves,embracing all those who's voice we can't hear, seeing we know what it's like... doing what's been done before is no different than doing it.

Bigger battery

Delphi not same as AC Delco. Delphi parts no where near quality of Delco. Delphi parted ways from Delco years back. Delco wanted more control and better quality. Hope it all works out. Great Videos! I work on cars all dat everyday and still like watching. Keep up the good work!

Could you have just pulled the bed of the truck off

fuel filter change ??

ya need AC DELCO, not AC DELPHI..

Don't you just love buying something and having to reengineer it to make it work. Why did I pay so much money?

Man you need to charge your camera more often or have an extra battery ready.

why didn't you buy one at the dealer you make trouble for your self

B

Just buy the 24 dollar ebay unit! LOL.

What a crappy aftermarket replacement. You shouldnt have had to all that wiring.

Stick to your Diagnostics in your fancy little tools and leave the mechanic work to a real mechanic geek boy

Butcher job