How to Install a Fuel Pump In a 1994 Chevy 2.2

One of the common signs the fuel pump in your 1994 Chevy 2.2 model is about to die is when it quits on you after being on the road for a few minutes. Other times, it will just stop working altogether. Your 1994 Chevy uses an electric in-tank fuel pump, which you can replace without completely removing the tank.

Instructions

Removing the Fuel Pump

1

Remove the fuel filler cap and siphon as much fuel out of the fuel tank as possible into an approved fuel container using a hand siphon pump. When finished, leave the fuel filler cap loose.

2

Detach the fuel pump fuse from the fuse block under the instrument panel.

3

Start your Chevy so the engine uses all the fuel remaining in the fuel lines. Once the engine stalls, turn off the vehicle, replace the fuel pump fuse and disconnect the negative battery cable with a wrench.

4

Raise the rear of your 1994 Chevy with a floor jack. Position a jack stand on each side under the frame for support. Lower the jack and chock the front wheels with two wooden blocks.

5

Put on your goggles and crawl under the vehicle. Unplug the electrical connector from the fuel pump and sender unit assembly on the top and front of the fuel tank.

6

Unscrew the muffler hanger bolts with a ratchet, large ratchet extension and socket. Detach the exhaust hangers from the rubber holders and rest the exhaust pipe on the rear axle.

7

Position the floor jack under the fuel tank, place a wooden block on the jack's saddle plate and support the fuel tank with the floor jack.

8

Unfasten the two straps that hold the fuel tank to the body of the vehicle using a ratchet, large ratchet extension and socket.

9

Lower the fuel tank a few inches and disconnect the fuel lines from the fuel pump and sending unit assembly on top of the tank.

10

Rotate counterclockwise a few inches the cam lock ring securing the fuel pump and sending unit assembly to the fuel tank to release the assembly. Use a drift punch and hammer.

11

Carefully lift the fuel pump and sending unit assembly out of the fuel tank and discard the large O-ring seal from under the assembly flange.

Replacing the Fuel Pump

12

Remove the strainer from the bottom of the fuel pump assembly and disconnect the electrical connectors from the fuel pump. Pull the pump up against the upper attaching hose and pull the bottom of the pump away from the bottom retainer. Slide the pump out of the assembly.

13

Install the new fuel pump following the reverse procedure described in Step 1 of this section and install a new strainer to the bottom of the fuel pump.

14

Replace the fuel pump and sending unit assembly into the fuel tank along with a new large O-ring seal. Secure the assembly to the fuel tank with the cam lock ring. Rotate the lock ring clockwise using the drift punch and hammer.

15

Reconnect the fuel lines to the fuel pump and sending unit assembly.

16

Raise the fuel tank to the installed position and secure it to the body of the vehicle with the two straps using the ratchet, large ratchet extension and socket. Remove the floor jack from under the vehicle.

17

Replace the exhaust pipe and muffler using the ratchet, large ratchet extension and socket. Plug in the electrical connector to the fuel sender unit assembly.

18

Lower your Chevy using the floor jack and remove the two wooden blocks from the front wheels.

19

Reconnect the negative battery cable with the wrench.

20

Refill your fuel tank with fuel and tighten the fuel filler cap.

21

Turn the ignition key to the On position to pressurize the fuel system and check for fuel leaks under the tank. Start and idle the engine. Check for fuel leaks under the fuel tank and then turn off the vehicle.