How to Replace an In-Tank Fuel Pump on a 2001 Chevy S-10

The 2001 Chevy S-10 compact pcikup uses an in-tank fuel pump. The fuel pump and the sending unit are one unit. Keeping the fuel pump in the tank keeps it cool and makes it so you can barely hear it as well. If it were outside the tank, you would be able to hear it pumping. If you are not getting fuel, check the fuel pump relay (in the engine compartment) and the wiring to the fuel pump before purchasing a replacement fuel pump.

Things You'll Need

• Set of sockets
• Set of wrenches
• Floor jack

Instructions

1. Disconnect the negative battery cable and lay it aside, ensuring that it does not touch metal. Pull the fuel pump relay out of the relay box, which is located on the driver’s-side fender well. The relay box cover tells you which relay goes to the fuel pump. Crank the S-10 over three or four times to relieve the fuel pressure in the system (it will not start).

2. Drain the fuel tank if it is more than half full. Slide the floor jack under the fuel tank and jack it up so that it touches the bottom of the tank. Loosen the bolts on the retaining straps enough so that the fuel tank comes down enough for you to reach the wiring and fuel lines. Disconnect the wiring and fuel lines. Carefully remove the bolts completely while balancing the fuel tank on the floor jack. Pull the tank out from under the vehicle.

3. Twist the cap, then carefully lift up to remove the fuel sender assembly. Unplug the fuel pump electrical connector. Remove the fuel sender assembly, taking care not to bend it, else the gauge will not work properly. Remove the retaining clip for the fuel level sensor, if there is one (it depends on the model of the S-10). Squeeze the tangs to remove the fuel level sensor. Remove the fuel pump from the assembly using the appropriate sockets.

4. Install the new fuel pump. Reinstall the fuel level sensor and the sensor retaining clip. Plug in the fuel level sensor electrical connector. Connect the electrical connector retaining clip. Plug in the fuel pump electrical connector, then carefully slide the assembly back into the tank. Lock the tabs on the cover.

5. Push the tank under the truck and jack it up just enough so that the wiring reaches the plug-ins for the fuel sender and pump assembly and you can still fit your hand between the tank and the car to plug it in. Reconnect the wiring and fuel lines. Jack the tank up the rest of the way. Bolt up the tank holding straps. Refill the tank. Plug in the fuel pump relay and reconnect the negative battery cable.

References

• Auto Zone: Repair Manual for 2001 Chevrolet S10