GMC Repair: Sputtering to stall, starting once cooled, gmc sierra, micron filter

Question
Info:    2002 GMC sierra pick-up V-6  engine 45,000 miles

Problem: After driving 100 plus mile or so truck will show “service engine light”, will run roughly (maybe). Once, I am slowed down it will sputter and stall and not start again.  It may almost catch but not for very long. Today, (the third time) I let it cool down and I could drive it to my destination, at least a short distance.

What has been done:  Took to 1st shop by tow truck. Shop said that the distributor cap was full of carbon and was “burned”, replaced the cap. Replaced the fuel filter. Tech said they ran it and was fine. One week later same problem towed it back to 1st shop. Tech reported that the starter was “burned out” and needed replacing.
Replaced starter.
Started the truck and drove 2 miles to shop 2. would not idle unless I eased down on the gas to keep it going.  Stalled in parking lot at shop 2.
Shop 2 found that the cap had excessive carbon and may need replacing.
Said that the pump was a little low should be in the 60 range or so and that it was reading in the high 50s.
Is it more than the fuel pump?
If it is the fuel pump, where is it located? Inside the tank or outside?
What are your suggestions?

Thank you,
Scott Poreda


Answer
GM has had this fuel pump problem for many years. Replace the pump and the micron filter (sediment/water filter that attaches on the bottom of the pump. Also make sure that the wires at the pump do not appear to look burnt as well.

The fuel pump is in the fuel tank and EXTREME care needs to be taken to drain out the gas, Remove the fuel tank, Replace the pump, micron screen and possibly the short wiring harness if it looks suspicious, as well as installing a new large "O" ring that seals the fuel meter assembly to the fuel tank.

Working with gasoline is VERY DANGEROUS and shuld NOT be attempted only by a professional person or facility. Not recommended for a novice.

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