Mechanics

CHEVY FUEL PUMP REPLACEMENT

1999 Chevrolet S-10

Engine Mechanical problem
1999 Chevy S-10 4 cyl Two Wheel Drive Manual 100000 miles

How difficult is it to replace the fuel pump and filter in this vehicle, I am led to believe it might involve remvoving the gas tank, is this true? Or is it just a matter of getting to the pumps location. What other concerns should I be aware of.
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Rmanguso
January 24, 2009.



I can answer that for you since I do not know your skill level. However, I will post the replacement procedures for your vehicle's fuel pump and fuel filter and let you decide for yourself. If you don't feel comfortable in doing the repairs, please let a reputable shop do the repairs to prevent damage to vehicle or harm to self.

FUEL PUMP REPLACEMENT
LOCATION:
The electric pump is attached to the fuel sending unit, located in the fuel tank.

REMOVAL:
Properly relieve the fuel system pressure by loosening the fuel filler cap.
Connect the negative battery cable.
Be sure to keep a Class B (dry chemical) fire extinguisher nearby.

CAUTION:
Due to the possibility of fire or explosion, never drain or store gasoline in an open container.

Drain the fuel tank, then remove it from the vehicle. Refer to the procedure found later in this section for details.
Using the GM fuel gauge sending unit retaining cam tool No. J-24187, J-36608 (or equivalent) or a brass drift and a hammer, remove the cam locking ring (fuel sending unit) by twisting counterclockwise. With the locking ring released, carefully lift the sending unit from the fuel tank.
Remove the fuel pump from the fuel sending unit, by performing the following procedures:
Pull the fuel pump up into the mounting tube, while pulling outward (away) from the bottom support.
When removing the fuel pump from the sending unit, be careful not to damage the rubber insulator and the strainer.
When the pump assembly is clear of the bottom support, pull it out of the rubber connector.

((A brass drift and a hammer can be used to loosen the fuel pump locking cam))


http://www.2carpros.com/forum/automotive_pictures/261618_0900c152800bfe3b_1.jpg



((Once the locking cam is released it can be removed to free the fuel pump))


http://www.2carpros.com/forum/automotive_pictures/261618_0900c152800bfe3c_1.jpg



INSTALLATION:
Inspect the fuel pump hose and bottom sound insulator for signs of deterioration, then replace, as necessary.
Push the fuel pump onto the sending tube.
Using a new sending unit-to-fuel tank O-ring, carefully lower the sending unit/fuel pump assembly into the fuel tank.
When installing the sending unit, be careful not to fold or twist the fuel strainer or it may restrict the fuel flow.
Secure the sending unit by turning or driving the lockring clockwise and into position under the tabs.
Install the fuel tank assembly to the vehicle.
Connect the negative battery cable and check for proper pump operation.

FUEL FILTER REPLACEMENT
LOCATION:
Under vehicle, passenger side, below bed area, mounted on frame in fuel line.

REMOVAL:
Properly relieve the fuel system pressure.
Remove the fuel filler cap.
Seperate the quick connect fittings from the filter. Refer to the quick connect fitting procedure is of this guide.
Remove the filter feed nut and the clamp bolt.
Remove the filter and the clamp from the vehicle.

INSTALLATION:
Position the filter and clamp with the directional arrow facing away from the fuel tank, towards the throttle body.
The filter has an arrow (fuel flow direction) on the side of the case, be sure to install it correctly in the system, the with arrow facing away from the fuel tank.
Attach and tighten the fuel feed nut.
Install and tighten the filter clamp assembly bolt.
Attach the fuel quick disconnect fittings to the filter. Refer to the quick connect fitting procedure is of this guide.
Install the filler cap.
Connect the negative battery cable, then start the engine and check for leaks.

Thanks for using 2CarPros.com!

Bluelightnin6
Jan 24, 2009.