How To Replace Fuel Pump 1994-2004 Chevy S 10

18-Apr-2022

Okay, friends, one of the first things we have to do to get started is to disconnect our negative battery terminal set that aside, so it's, not making any contact with the battery we're going to continue on by removing our clamps that hold the hoses to the filler neck itself. I like to spray everything down with a good amount of penetrant now we're going to continue with a quarter inch ratchet and an eight millimeter socket and start loosening this clamp. The first hose I'm going to take off is this. One right here that way there it's out of the way? So I can remove the next clamp.

Okay, that's, nice and loose. Let's. Go ahead and slide it out of the way now let's continue with this right here. We're going to get in between the filler neck and the hose itself and just try to separate the two. I want to be very careful, not to damage the hose that leads down to the fuel tank. Okay.

So now that we went ahead and broke this one free, let's continue on to removing the larger one. Now just going to do the. Same thing loosen up the clamp, and then of course, we'll get around it with that pick and break it free I'm just going to use my pry bar come right up in between the frame area here careful with any brake lines.

You might have and let's just try to separate the filler neck from those hoses. So now that we have the hoses off let's, go ahead and climb underneath the driver's side of the truck. Your fuel tank is going to be located right here.

But there's, also a metal shield, that's going to be in the way. To remove the fuel tank. So the first thing that we need to do is go ahead and get the shield out of here you're going to notice that you have a mounting bolt that comes through from the outer portion of the frame coming through here. Here, we're going to come right up here and remove this one as well, then we'll come right down here remove this and then up here, and we'll, remove those two nuts and bolts as well. There's one. Now, we're going to remove these two bolts right here, you're going to notice that.

You're going to have to hold the nuts on the forward side, and then we'll remove the bolt from the rearward side. There's, one, let's do the same together now let's hold off on removing this not right here, and we're going to move over towards the driver's side and remove these two mounting bolts as well. Now, let's move back over towards the front of the tank, I'm just going to go ahead and grab onto this. Give it a nice little wiggle so that it clears this wiring area here if yours doesn't wiggle, you can.

Go ahead and try to loosen this a little now we're going to move over here. And remove this not just keep in mind. This is pretty much the only thing holding up the shield. So once we remove it you're going to have the entire weight of the shield coming down.

Now, we're just going to put something underneath the center of the fuel tank. So we can support it. And of course, we also are going to need to be able to lower this down after we've removed the mounting hardware let's start with the rearward.

Bolt right here, bolts out let's, go ahead and bend this down and out of the way now let's move along to the driver's side outside frame, you're going to find that there's four bolts, one, two, three and the other one's going to be hidden right behind here. So this one's going to be the last one that we removed let's remove the first three. The next thing I want to do is go ahead and get this e-brake cable right out of the way essentially I'm just going to go ahead and squeeze on the tabs that are holding. It into this bracket and then pull it. So it gets to the point where it's here now we can move it out of the way. So we can get the bolt out I'm just going to use a tool that looks like this it's going to go over. You can also use pliers if you can get it around all the ears there.

We are now we'll just pull this out of the way. And now we have complete access to that bolt now, we're just going to come underneath here, and we're going to try to pull this bracket away from the area of the frame. So.

That way there we can remove the fuel tank, where am I going to go? Let's? Go ahead and carefully start lowering it down all right. So now with the fuel tank as low as we can go, we have it at an angle.

The reason for that is because I want to start removing all these fuel hoses, and then we're going to move along to removing the electrical connector as well. Now for two of these fuel, hoses, what you're going to realize you're going to have two little squeeze tabs? You go ahead and squeeze on them, it's. Going to release the line just be careful because there is probably fuel inside the lines just going to squeeze right here in here, give this a nice wiggle and draw it off this. One right here in the center is going to be a little different, so we're going to save that one for last I'll just continue on by removing this other one right here there we are. We've got some fuel coming out now for this one it's got different types of squeeze tabs it's. Basically, just these little, uh, circular rings off.

To the sides, if you were to just go ahead and squeeze on those it's going to separate the tabs, and then you can draw this off as well, all right that one's off as well, let's move along to the electrical connector. Okay. So now, the next thing we're going to do is remove our electrical connector you're going to notice up along the rearward side, or along the driver's side of it. I should say, there's going to be a gray locking device. Essentially it's, just a piece of plastic I'm going to come in between.

The center try to push down, and then try to pry that gray locking tab away there. We are now let's. Go ahead and squeeze on this center tab and then draw the electrical connector away from the fuel tank perfect now that we have the larger one off let's continue on to the smaller one. This one right here, you can just go ahead and grab onto this tab lift it up, and then we'll draw it away from the fuel pump. Now, with all that disconnected let's, go ahead and carefully, lower our fuel tank, we're going to. Do this slowly, because of course, we have the hoses that go up and over the frame for the filler neck. Now that we have the fuel tank safely down on the ground, we're going to continue on by spraying off all the debris that's in this localized area, essentially the reason for that is because we need to take off this clip.

And also, because when we remove the fuel pump from the tank, we want to make sure that no debris falls inside all right. So now, the next thing we want to do now that we've sprayed. This down and let it sit for a little while is to continue on with a brass punch and a hammer, and I'm just going to work my way around this locking clip here, essentially just breaking it free from the fuel tank. Now, I'm just going to use some snap ring pliers. They have the little tips on them, and they're going to fit into the holes for the snap ring. This one kind of came out when I was bonking on it. But essentially, if you just put your snap ring clear into the holes and then squeeze on it, we're.

Going to be able to release that locking clip, and then remove it from the tank let's, give this another blast with air. The next thing we're going to do is go ahead and pry the fuel pump up from the fuel tank, let's, go ahead and carefully lift this up and out of here, it's still going to have fuel in it. So you're going to want to make sure that you dump that into a recycling bin. Okay, friends now it's going to be time to prep our new fuel pump. We have our float right here.

It's going to be important. To make sure that you set. So the piton goes into the hole right here. And then the shaft goes along this area there and clips in just slide it straight in. And then listen for a click, give it a nice, wiggle make sure it's completely secured.

You definitely don't want this to fall off once it's in the fuel tank. So now we're going to go ahead and put this in lets's, go ahead and put the float in, and it's going to go towards the rear of the vehicle as we bring this down we're going to line up this tab. Right here with the area on the fuel tank where it needs to go, and we'll leave it just like this next we're going to take our o-ring carefully, put it up and over this, and then we're just going to gently stretch it over now let's, go ahead and press this down into where it needs to go. Remember to line up your tab now, let's grab our clip, just slide it around here, I'm going to line it up press down on the fuel pump, and we'll start putting our clip around last one and help it in there we are. Now just make sure the clip's sitting completely inside all the way around the fuel tank. Now, let's just make sure that all the covers are nice and loose.

So we can easily remove them once we get the tank up and inside the truck now, looking at our original fuel pump. The next thing we have to do is go ahead and remove these clips right here, we're going to reuse those into the original lines. So let's, go ahead and lift on the tab after you've done that just give it a little pry and push it up over. The lip we'll do the same on the other tab and then slide it right off do the same to both. So now that we removed our clips, and we cleaned them off the next thing I want to talk about is the two different sizes you're going to see the one in my right hand, right here is a little larger than the one in my left. If you were to look at your lines right up here, you're going to notice that the line that's towards the rear of the truck is going to be smaller than the one that's all the way towards the. Front so let's, go ahead and put them into the corresponding holes clips in do the same to the other one.

And of course, the center one does not have one of these clips. Go ahead and start putting our fuel tank up before we put it all the way up, though let's make sure that we connect in our electrical. And of course, our fuel lines the larger. The electrical connector is going to go towards the front of the truck, the forward connector, push it in give it a nice click and make sure it's secure next we're. Going to go ahead and do the smaller one that's going to be towards the rear of the fuel pump, go ahead and slide that in listen for a click there. It is give it a pleasant, wiggle secure as well. Let's, go ahead and get the little gray lock for this.

Now. Now on the larger, one let's, go ahead and push in our gray lock now we're going to go ahead and do the fuel lines. Let's just pull off all these caps we'll set those aside next we're going to start connecting in our fuel lines we're going to take the. Larger one, which is the forward, one that's going to go into the forward aspect of the fuel pump right here.

Go ahead and push it in listen for a click, give it a pleasant tug. You will definitely want to make sure that all of your fuel lines are completely secured the center. One is the one that does not have a clip on it.

Let's, go ahead and put that in as well, give it a pleasant tug. And then, of course, last, but not least the rearward line give it a pleasant click and a nice tug perfect. Now that we have the upper.

Lines connected the next thing we want to do is go ahead and jack this up so that our brackets lined up with the area on the frame that it needs to be at the same time, we're doing that, though we need to pay attention to the fuel hoses, which are located up on top of the fuel tank. We want to make sure that those hoses line up with our filler neck. Okay. Now that I have those holes semi-lined up, let's, go ahead and start in a couple of the bolts. Okay. So now that I've got them lined up, let's, go ahead.

And start in all four of our bolts before we snug any of them up now we're going to go ahead and tighten up all of our bolts now that those are nice and snug let's, go ahead and put in our e-brake cable perfect. Now that we tightened up the bolts for the front strap let's continue on to the bend rear right up along here. You can tell that it fits inside the groove of the fuel tank, we're going to bring this right up along this area here, let's continue on with this piece. Right here.

You can tell that. It has a little hook you do that hook is going to go around this right here. And then it should sit up along the top there. So we can take our bolt slide it right through both of these here, and then we'll line it up with our mounting hole and start in this bolt as well. Now, we're just going to torque both straps to 13 foot pounds. Now we can get the jack out of here. Okay.

So now let's, go ahead and line up. Our filler neck with those hoses if it's hard to get them, one of them on there, just go ahead and. Use your little hook slide this around the tube all right. So now that we have those slid on let's continue on by tightening up, both of our clamps. Okay. Now, it's going to be time to go ahead and get our shield up on there.

We've got this bracket here that needs to go up and over the drive shaft. So I'm just going to go ahead and turn this at an angle, put it up over the drive shaft. And then put the other end over the leaf spring there. We are I'm, just going to go ahead and use a washer. And the nut start.

That on here, okay, so now let's, go ahead and line up our shield. So the boltholes line up with the frame of the truck here we're going to use our two long bolts that look like this. Go ahead and slide them through the shields through the frame and then right out the other side. Now, with both bolts through let's, go ahead and start on the nuts.

So now we're going to come to the front of the tank we're going to start in the other bolts here as well. Okay. So I'm just going to go ahead and lift on this. And then I'm going to take my bolt on my socket with an extension come through the frame and start it in let's get that bolt in there.

Okay. Now, let's, go ahead and start in our forward. Bolt now let's, go ahead and start in our rearward bolts. Okay.

So now that we have all of our mounting bolts started on our shield, let's continue on by snugging them all up all right let's. Not forget this one as well. Okay. Now back up at the front of the truck, let's, go ahead and reconnect. Our negative battery terminal. And snug it up give it a nice, wiggle make sure it's secure, okay, friends. Now, all you have to do is hop in the driver's side of the truck, and we're going to take that key and put in the on position, we're going to listen for the fuel pump.

You want to make sure it primes the lines after that turn the key to the off position and then back to the on position and start it. After that point you want to make sure you take a peek underneath the truck and make sure you don't have any fuel leaks. Then take it. For a road test you.

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