How to Change an S10 Fuel Pump

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Changing your Chevy S10 fuel pump is a simple procedure if you take proper precautions and follow a few simple steps. Make sure you have all the tools and replacement components before you begin.

Things You'll Need

  • Small screwdriver
  • Shop rag
  • Approved fuel container
  • Hand siphon pump
  • Screwdriver
  • Ratchet and socket set
  • Drift punch and soft hammer

Change Your Chevy S10 Fuel Pump

  • Park your Chevy S10 in a safe place with a level surface. Make sure you have enough room to work around the truck.

  • Unplug the fuel pump relay, which is located in the fuse/relay box in the engine compartment on 1995 to 1997 2.2L engine models. Markings on the relay or the back of the fuse box lid should identify the relay. On other models, press the small stem inside the Schrader valve--similar to a bicycle-tire valve--located on the fuel inline rail, right before the first fuel injector. Cover the valve with a shop rag as you depress the stem with a small screwdriver to catch the squirt of fuel.

  • Disconnect the black, negative battery cable and raise the rear of the truck with a floor jack. Safely support it on two jack stands.

  • Drain the fuel tank into an approved container through the filler pipe. Use a hand siphon pump if necessary.

  • Disconnect the clamp from the filler hose at the tank with a screwdriver and remove the hose. Remove the tank shield. Support the fuel tank with a floor jack and a piece of wood on the jack pad to avoid damage to the tank.

  • Remove the tank-holding straps with a ratchet and socket.

  • Lower the fuel tank so you can disconnect the fuel lines from the fuel pump/sending unit assembly on top of the tank. Unplug the pump electrical connector and lower the tank to the floor.

  • Turn the lock-ring tabs holding the pump/sending unit assembly to the tank counterclockwise with a drift punch and a soft hammer until the ring is released.

  • Lift the pump/sending unit assembly off the tank, remove the pump and install the new pump in the pump/sending unit assembly. Discard the pump/sending unit O-ring seal.

  • Install a new pump/sending unit O-ring and set the pump assembly in the tank.

  • Lock the assembly lock ring by turning the ring clockwise until it locks in place.

  • Connect the fuel lines to the to the fuel/sending unit assembly and plug the pump electrical connector.

  • Raise the tank to its mounting position and install the tank-holding straps. Install the tank shield and connect the filler neck to the tank.

  • Lower the truck, plug the fuel-pump relay and connect the black, negative battery cable.

  • Refill the fuel tank, start the engine and check for leaks.

Tips & Warnings

  • When working on the fuel system of your vehicle, do not allow smoking near or around the car and park away from appliances with open flames, such as water heaters and dryers.

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  • Photo Credit gas pump image by jedphoto from Fotolia.com
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