How to Change a Fuel Pump in an S-10 Pickup

The fuel pump is the center of your Chevy S-10 pickup truck fuel system. It delivers fuel under high pressure to the engine. But after years of service, fuel pump components wear out, and you may experience fuel pump problems when your engine stalls, hesitates or lacks power. The only way to correct the problem is to replace the pump. If you want to do it yourself, just follow these simple steps to install a new unit in your truck. The method is based on a 2000 model with an in-tank fuel pump, and many other models are similar.

Difficulty: Moderate

Instructions

Things You'll Need:

• Jack and 2 jack stands
• Wrench set
• Ratchet and socket set

1. Park your S-10 pickup in a safe and level place with enough room at the back for you to work.

2. Make sure the gas tank is almost empty or siphon the gas out of the tank through the filler pipe.

3. Relieve the fuel system pressure. The easiest way to do this is by pulling the fuel pump fuse from the fuse box or panel. Start the engine until it stalls from lack of fuel and reinstall the fuse.

4. Raise the back of the truck with a floor jack and support it safely on jack stands.

5. Disconnect or remove the black, negative battery cable, filler neck and shield from the gas tank using wrenches or ratchet and sockets.

6. Support the tank with a jack and disconnect the tank straps using a ratchet. Carefully lower the tank to the floor.

7. Disconnect the fuel lines and fuel pump electrical connector going into the cam lock unit.

8. Rotate the cam lock tabs counterclockwise with a long punch and light hammer blows, and carefully lift the fuel pump and sending unit off the fuel tank.

9. Remove the old fuel pump and install the new unit, then install the assembly in place inside the tank, making sure to properly set the ring seal underneath the cam.

10. Connect the fuel lines and fuel pump electrical connector; raise the fuel tank and torque the straps to 33 foot pounds (45 Nm); connect the filler neck and shield to the tank; finally, lower the truck and connect the black, negative battery cable.

11. Fill the gas tank, start the engine and check for possible leaks.

Tips & Warnings

• Consult your vehicle service manual if you need to locate or identify components. You can buy one at most auto parts stores or consult one for free at most public libraries.
• Any time you need to work on your truck's fuel system, make sure to park away from open flames like water heaters and dryers to avoid an accident.

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