Here's a general outline. Specific steps may vary slightly depending on your truck's configuration. Consult a repair manual specific to your 1991 S-10 2.8L V6 for detailed instructions and diagrams. This is crucial as variations exist.
1. Preparation:
* Safety First: Disconnect the negative battery terminal. This is vital to prevent sparks near fuel.
* Gather Tools: You'll need jack stands, a jack, sockets (various sizes), wrenches, screwdrivers, fuel pump pliers (or similar tool to remove the retaining ring), a fuel line disconnect tool, rags, safety glasses, gloves, and potentially a torque wrench.
* Obtain a New Fuel Pump: Ensure you get the correct fuel pump for your specific vehicle. The part number should be available from your local auto parts store.
* Drain Fuel: If possible, carefully drain some fuel from the tank to reduce the amount of fuel you'll be working around.
2. Accessing the Fuel Pump:
* Lower the Fuel Tank: This is usually the most involved step. You'll need to access the fuel tank from underneath the truck. This often involves:
* Supporting the tank securely with jack stands. Never work under a vehicle supported only by a jack.
* Locating and disconnecting the fuel lines. Use the disconnect tool to avoid damaging the lines. Be prepared for fuel spillage. Have rags ready.
* Disconnecting the fuel tank electrical connector.
* Unbolting the fuel tank straps. These may be difficult to access.
* Carefully lowering the tank enough to access the fuel pump.
* Alternative Access (if applicable): Some models may have an access panel in the bed allowing access to the pump without completely dropping the tank. Check your repair manual.
3. Removing the Fuel Pump:
* Remove the Access Cover: Once the tank is lowered sufficiently, you'll find a cover over the fuel pump. Remove this cover.
* Disconnect Electrical Connector: Disconnect the fuel pump electrical connector.
* Remove the Retaining Ring: Use fuel pump pliers or a similar tool to carefully remove the retaining ring holding the fuel pump in place.
* Remove the Fuel Pump: The pump should lift out.
4. Installing the New Fuel Pump:
* Install the New Fuel Pump: Carefully install the new fuel pump, ensuring the gasket is properly seated.
* Install the Retaining Ring: Securely replace the retaining ring.
* Reconnect the Electrical Connector: Reconnect the fuel pump's electrical connector.
5. Reassembly:
* Raise the Fuel Tank: Carefully raise the fuel tank back into its position.
* Reconnect Fuel Lines and Straps: Securely reconnect the fuel lines and straps. Make sure the connections are tight.
* Reconnect Electrical Connector: Make sure the fuel tank's electrical connector is securely connected.
* Lower the Jack Stands and Jack: Carefully lower the jack stands and jack.
6. Post-Installation:
* Reconnect Battery Terminal: Reconnect the negative battery terminal.
* Check for Leaks: Carefully check all fuel lines and connections for leaks.
* Start the Engine: Start the engine and listen for unusual noises. Check for any leaks.
* Run the Engine: Let the engine run for a while to ensure the fuel pump is working correctly. Check for fuel pressure (if you have a gauge).
Important Considerations:
* Fuel Pressure: Some fuel pumps need to be primed before starting. Consult your repair manual.
* Safety: Gasoline is extremely flammable. Work in a well-ventilated area and avoid any sources of ignition.
* Repair Manual: This is a crucial tool. It will provide precise instructions and diagrams specific to your vehicle.
This is a general guide. Improper installation can lead to serious problems, including fire. If you are not comfortable performing this repair, take your vehicle to a qualified mechanic. This process involves working with flammable fuel; safety is paramount.
