xXxPARAGONxXx’s 1999 Chevrolet K2500 Crew Cab

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BBslider001

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Caman96

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xXxPARAGONxXx

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Dropped the fuel tank last week and removed the fuel pump harness that runs from the fuel pump all the way to the firewall. Based on the wiring having a pigtail spliced in, previous owner installed an aftermarket fuel pump. To be expected after 300,000 miles though. (I'm actually wondering if this vehicle has 300,000 legitimate miles or whether the speedometer was off due to larger tires.)

It appears the previous owner installed a fuel pump intended for the California emissions RPO code, as this fuel pump has a fuel tank pressure sensor which my RPO is not supposed to have. That's probably why there was no actual harness connector plugged into the fuel tank pressure sensor (black connector). There was only a harness connector plugged into the main fuel pump (white connector).

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I need to empty the fuel tank of gasoline and wash it, inside and outside. This fuel's been sitting in there for maybe 10 months now, so have to get rid of it. Will be installing a new fuel pump and replacing the in-line fuel filter.

With respect to the wiring harness, I measured the wire lengths and re-made the harness. I upgraded all the wires to 1.0 mm (16 gauge), same color as stock (two black, one gray, one purple with white stripe). Well, all upgraded to 1.0 mm except for the purple wire with white stripe, which I had to use 0.8 mm (18 gauge), as the vendor was out of stock for the 1.0 mm (16 gauge) size. But, it's still an increment larger than the 0.5 mm (20 gauge) stock wiring. Used a new Aptiv GT 280 4-terminal sealed connector, all new terminals and seals on each end, and also crimped on a new ring ground terminal. All new harness. I just have to finish taping it and re-looming it, but no rush at the moment.

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Almost done replacing the wiring on the instrument panel harness. Once I get the harnesses finished and replace the fuel pump and wash the fuel tank, then I will focus on re-building the front differential, as I will finally have room on the workbench.
 

Supercharged111

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Dropped the fuel tank last week and removed the fuel pump harness that runs from the fuel pump all the way to the firewall. Based on the wiring having a pigtail spliced in, previous owner installed an aftermarket fuel pump. To be expected after 300,000 miles though. (I'm actually wondering if this vehicle has 300,000 legitimate miles or whether the speedometer was off due to larger tires.)

It appears the previous owner installed a fuel pump intended for the California emissions RPO code, as this fuel pump has a fuel tank pressure sensor which my RPO is not supposed to have. That's probably why there was no actual harness connector plugged into the fuel tank pressure sensor (black connector). There was only a harness connector plugged into the main fuel pump (white connector).

You must be registered for see images attach


I need to empty the fuel tank of gasoline and wash it, inside and outside. This fuel's been sitting in there for maybe 10 months now, so have to get rid of it. Will be installing a new fuel pump and replacing the in-line fuel filter.

With respect to the wiring harness, I measured the wire lengths and re-made the harness. I upgraded all the wires to 1.0 mm (16 gauge), same color as stock (two black, one gray, one purple with white stripe). Well, all upgraded to 1.0 mm except for the purple wire with white stripe, which I had to use 0.8 mm (18 gauge), as the vendor was out of stock for the 1.0 mm (16 gauge) size. But, it's still an increment larger than the 0.5 mm (20 gauge) stock wiring. Used a new Aptiv GT 280 4-terminal sealed connector, all new terminals and seals on each end, and also crimped on a new ring ground terminal. All new harness. I just have to finish taping it and re-looming it, but no rush at the moment.

You must be registered for see images attach


Almost done replacing the wiring on the instrument panel harness. Once I get the harnesses finished and replace the fuel pump and wash the fuel tank, then I will focus on re-building the front differential, as I will finally have room on the workbench.

More likely scenario is he got a pump and sender for a half ton as those had the sensor outside of CA.
 

xXxPARAGONxXx

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Started disassembling the front axle.

Removed the driver's-side axle shaft using a slide hammer.

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