The process is significantly different depending on whether your fuel pump is located inside the fuel tank (in-tank) or outside (in-line, which is less common on S10s of that era). Almost certainly, it's an in-tank pump.
Replacing the Fuel Pump (the practical approach):
Here's a general outline for replacing the fuel pump assembly on a 1997 Chevy S10 V6 with an in-tank pump. Always disconnect the negative battery terminal before starting any work.
1. Safety First: Fuel is flammable. Work in a well-ventilated area, away from any open flames or sparks. Consider using safety glasses and gloves.
2. Lower the Fuel Tank: This is the most involved part. You'll need to:
* Disconnect the fuel lines: Carefully loosen the fuel lines using appropriate wrenches. Have rags ready to absorb any spilled fuel. You might need a fuel line disconnect tool for easier separation.
* Disconnect the electrical connector: Unplug the electrical connector from the fuel pump.
* Remove the fuel tank retaining straps: These usually involve bolts and nuts.
* Carefully lower the fuel tank: This often requires a fuel tank strap wrench or similar tool and maybe a helper. Be mindful of the fuel lines and the electrical connector.
3. Access the Fuel Pump: Once the tank is lowered (or partially lowered, depending on space), you'll see the fuel pump assembly at the top of the tank.
4. Remove the Fuel Pump Assembly: This usually involves removing a retaining ring or a few bolts. There might be a lock ring. Refer to a repair manual specific to your S10 for exact details.
5. Install the New Fuel Pump Assembly: This is the reverse of the removal process. Ensure the new pump assembly is correctly seated.
6. Raise the Fuel Tank: Carefully raise the fuel tank back into its position.
7. Reconnect Everything: Reconnect the fuel lines, electrical connector, and retaining straps. Double-check all connections.
8. Prime the Fuel System (Important): After reassembly, you might need to prime the fuel system to get the engine started. This could involve turning the ignition key several times (without starting the engine) to build fuel pressure. Some vehicles require a specific priming procedure. Consult your repair manual.
Why not rebuild?
* Cost: The cost of parts and the specialized tools needed for a rebuild often exceed the cost of a new fuel pump assembly.
* Complexity: The fuel pump assembly isn't easily disassembled and cleaned. Internal components are precisely engineered and are difficult to reassemble properly.
* Reliability: A rebuilt fuel pump might not perform as well or last as long as a new one.
Important Note: This is a general overview. A repair manual specific to your 1997 Chevy S10 V6 is crucial. These manuals provide detailed instructions, diagrams, and torque specifications. Using a repair manual is highly recommended to avoid damaging your vehicle. If you're not comfortable performing this repair yourself, take your vehicle to a qualified mechanic.
