Here's a general outline. Specific steps may vary slightly depending on the exact model and trim of your S10. Always consult a repair manual specific to your vehicle year and engine for detailed instructions and diagrams. A Haynes or Chilton manual is a good investment.
1. Preparation:
* Safety First: Disconnect the negative battery cable.
* Gather Tools: You'll need jack stands, a jack, wrenches (various sizes), sockets, ratchet, fuel line disconnect tools, possibly a fuel pump pliers (for fuel lines), safety glasses, gloves, and possibly a fuel pump installation kit (sometimes includes a new fuel filter). A torque wrench is highly recommended.
* Locate the Fuel Pump: The fuel pump is usually located inside the fuel tank. Access will require dropping the fuel tank.
* Drain the Fuel Tank: This significantly reduces the risk of fuel spillage. Use a siphon pump or carefully drain fuel through the fuel line after disconnecting it from the tank. Never work near open flames or sparks. Dispose of the fuel properly.
2. Dropping the Fuel Tank:
* Disconnect Fuel Lines: Carefully disconnect the fuel supply and return lines. Use fuel line disconnect tools to avoid damaging the lines. Have rags ready to absorb any spilled fuel.
* Disconnect Electrical Connections: Disconnect the electrical connector to the fuel pump.
* Disconnect Fuel Tank Sender Unit (If applicable): This is the unit that measures fuel level and may be part of the fuel pump assembly.
* Disconnect Fuel Tank Straps: Loosen and remove the straps or bolts securing the fuel tank.
* Lower the Fuel Tank: Carefully lower the fuel tank. You may need to support it with a jack or straps to prevent it from falling.
3. Replacing the Fuel Pump:
* Access the Fuel Pump: The fuel pump is usually accessed through a hatch or by removing the top of the fuel tank. Your repair manual will show you the correct method.
* Remove the Old Fuel Pump: Carefully remove the old fuel pump, noting the orientation and position of any components (especially the fuel level sensor).
* Install the New Fuel Pump: Install the new fuel pump, ensuring it's seated correctly. Often there's a gasket or seal to replace as well.
* Reassemble: Reassemble everything in reverse order of disassembly.
4. Reinstallation:
* Raise the Fuel Tank: Carefully raise the fuel tank back into position.
* Reconnect Fuel Tank Straps and Connections: Secure the fuel tank with the straps and reconnect all fuel lines and electrical connectors.
* Reconnect Battery: Reconnect the negative battery cable.
5. Priming the System:
* Check for Leaks: Check for any fuel leaks around the fuel lines and connections.
* Prime the Fuel System: You may need to crank the engine for a few seconds (without starting) to prime the fuel system. This allows the pump to build pressure before starting.
* Start the Engine: Start the engine and check for any issues.
Important Considerations:
* Safety: Fuel is highly flammable. Work in a well-ventilated area away from any ignition sources. Use proper safety equipment.
* Repair Manual: This is crucial. Pictures and detailed instructions are invaluable.
* Fuel Pressure: After installation, you may want to check the fuel pressure to ensure the new pump is working correctly. This usually requires a fuel pressure gauge.
This is a general guide. Improper installation can lead to serious problems, including fire. If you're not comfortable performing this repair, take your vehicle to a qualified mechanic. They have the experience and tools to do the job safely and correctly.
