The electric fuel pump on the 2003 Chevy Suburban resides below the chassis in the fuel tank. The fuel lines and electrical connections are routed above the tank into the top of the fuel pump. Therefore, to reach the fuel pump, the fuel tank has to come off. Although this is a time-consuming task, it is rather straightforward.
Open the hood of the 2003 Suburban. Disconnect the negative battery cable. Remove the fuse and relay from the fuse and relay box that operate on the fuse pump circuit.
Open the driver's side gas filler cap. Put the nozzle of the siphon into the gas filler pipe. Insert the other end of the siphon to the gas can. Pump out the gas from the Suburban's fuel tank into the gas can. This action relieves the weight of the fuel from the tank and ensures that fuel doesn't spill on you when you move the tank and the pump.
Chock the front wheels. Raise the rear of Suburban with your floor jack. Place two jack stands under the frame, and lower the Suburban on the stands.
Put on your latex gloves. Loosen the metal collar ring of the filler pipe hose on the side of the gas tank. Pull the hose off of the tank. Repeat this process for the vent hose on the side of the tank.
Position the floor jack below the gas tank. Remove the bolt holding the forward fuel tank strap. Push the strap out of the way. Pry the fuel tank away from the frame rail to have the forward end of it drop onto the floor jack.
Disconnect the now-visible hoses and lines from the fuel pump. Depress the tabs of the wiring harness. Twist off the fuel return and EVAP hoses. Remove the final strap. Pull the fuel tank on the floor jack into a position where you can see it fully.
Clean the area around the fuel pump on the tank with an acetone cleaning agent. This prevents contaminants from getting into the fuel tank.
Remove the locking ring from around the fuel pump. Hit each tab on the locking ring with your hammer and brass punch in a counterclockwise direction. Using the brass punch will ensure that you don't create sparks. This loosens the tabs from the slots of the fuel tank.
Pull out the fuel pump and o-ring gasket.
Lubricate the new o-ring gasket with a smear of motor oil. Set the gasket below the head of the fuel pump. Slide the fuel pump into the fuel tank. Orient the stems of the fuel pump between the hatch mark grooves on the surface of the fuel tank. Lock the fuel pump into place by remounting the locking ring with the hammer and brass punch.
Remount the fuel tank and reconnect the hoses and electrical connection.
Reconnect the battery and the fuel pump fuse and relay.
Refill the gas in the fuel tank.
Turn the ignition to "On." Wait 10 seconds. Turn the ignition to "Lock." Repeat this process at least three more times. This action turns on the fuel pump and sends fuel through the fuel system. Check below the Suburban for any fuel leaks. Tighten any fittings that are leaking. Remove the car jack and jack stands.
