How to Replace the Fuel Pump on a 1992 Chevy Caprice

Removing the Fuel Pump

• 1). Park your Caprice on level ground, turn off the ignition key and set the transmission to neutral.
  
  
• 2). Disconnect the black battery cable using a wrench.
  
  
• 3). Drain the tank through the fuel filler tube using a hand siphon pump into an approved container, if necessary, and store in a safe place.
  
  
• 4). Leave the fuel filler cap loose to relieve fuel-system pressure.
  
  
• 5). Raise the rear of your Caprice with a floor jack, support it on two jack stands and chock the front wheels.
  
  
• 6). Crawl under your car and remove the fuel-tank shield using a ratchet, ratchet extension and socket.
  
  
• 7). Loosen the vapor hose clamp at the fuel sender/pump assembly on top of the fuel tank using a Phillips screwdriver.
  
  
• 8). Support the fuel tank with the floor jack and detach the two mounting straps using the ratchet, ratchet extension and socket.
  
  
• 9). Lower the fuel tank just enough to reach and disconnect the fuel feed and return lines from the fuel sender/pump assembly. Press the side tabs on the hose connectors and separate the lines from the assembly fittings. Use a shop rag to absorb any residual fuel from the lines.
  
  
• 10
  
  Unplug the fuel sender/pump assembly electrical connector.
  
  
• 11
  
  Lower the fuel tank and unfasten the retaining-ring nuts from the fuel sender/pump assembly using a ratchet, ratchet extension and socket.
  
  
• 12
  
  Lift the fuel sender/pump assembly from the fuel tank, discard the O-ring seal under the assembly and remove the unit from the vehicle.
  
  
• 13
  
  Take the fuel pump off the assembly using a pair of needle-nose pliers and a Phillips screwdriver.
  
  

Installing the New Fuel Pump

• 1). Install the new fuel pump into the assembly using the pair of needle-nose pliers and a Phillips screwdriver.
  
  
• 2). Place a new O-ring seal on the fuel tank opening and insert the fuel sender/pump assembly into the tank.
  
  
• 3). Fasten the assembly retaining-ring nuts using the ratchet, ratchet extension and socket.
  
  
• 4). Raise the fuel tank with the floor jack just enough to plug the fuel sender/pump assembly electrical connector and connect the fuel feed and return lines to the fuel sender/pump assembly.
  
  
• 5). Raise the fuel tank into its mounting position using the floor jack and replace the two mounting straps using the ratchet, ratchet extension and socket. Then remove the floor jack.
  
  
• 6). Attach the vapor hose to the fuel sender/pump assembly and secure it with the clamp using the Phillips screwdriver.
  
  
• 7). Replace the fuel-tank shield using the ratchet, ratchet extension and socket.
  
  
• 8). Lower your vehicle using the floor jack.
  
  
• 9). Refill the fuel tank.
  
  
• 10
  
  Connect the black battery cable using the wrench.
  
  
• 11
  
  Turn the ignition key to the "On" position for five seconds. Turn the ignition "Off" for 10 seconds and "On" again. Check for fuel leaks at the tank and turn off the ignition.