Replacing Fuel Pump In 2002 S10: Step-By-Step Guide

The fuel pump is an essential part of a vehicle's fuel system, delivering fuel from the tank to the engine. If you're looking to replace the fuel pump on a 2002 S10, there are a few methods you can choose from. One option is to drop the fuel tank and access the pump from underneath. This method can be tricky and time-consuming. An alternative approach is to remove the bed of the truck to gain access to the top of the fuel pump. While this method may require assistance from a few friends, it is generally considered to be easier and quicker. Whichever method you choose, remember to exercise caution when working with fuel systems and always seek help from a qualified professional if you're unsure.

Disconnect the fuel pump relay

Disconnecting the fuel pump relay is one of the first steps in changing the fuel pump on a 2002 S10. Here is a detailed, step-by-step guide on how to do it:

Locate the Fuel Pump Relay

The fuel pump relay is usually located in the vehicle's long black box, along with the other relays and fuses, in the engine compartment. However, the location may vary depending on the car model. In the 2002 S10, the fuel pump relay is located in the fuse/relay box in the engine compartment.

• Turn on the ignition key to the "run" position and listen for the fuel pump to activate. Also, listen for any buzzing or clicking noise coming from the fuel pump relay.
• Start the engine and check the oil pressure. You can look for an oil light indicator on your dashboard; when the indicator light goes out, it means there is oil pressure.
• Park your vehicle on a flat, level surface and engage the parking brake. If you are working on a slope or uneven ground, make sure to use wheel chocks to secure the front tires and prevent the vehicle from moving.
• Disconnect the battery by opening the vehicle's hood and removing the ground cable from the battery's negative post. This will disable the power to the fuel pump and sending unit.
• Locate the fuse box in the engine compartment. It is usually located near the battery. If necessary, use a ratchet to remove any hex screws or bolts holding the cover in place.
• Remove the cover of the fuse box and locate the fuel pump relay. Refer to the diagram on the fuse box cover or your owner's manual to identify the correct relay. Some fuse boxes may not have diagrams, so the owner's manual will be helpful in such cases.
• Pay attention to how the relay is positioned within the fuse box, as the new relay needs to be installed in the same way. Carefully remove the fuel pump relay. You may need a pair of needle-nose pliers to pull it out gently.

Once you have successfully disconnected and removed the old fuel pump relay, you can proceed to install a new one. Make sure to follow the installation steps carefully to ensure a proper connection.

Drain the fuel tank

To drain the fuel tank of your 2002 S10, you will need to first park your vehicle on a level surface and disconnect the negative battery cable. You will then need to raise the rear of the truck using a floor jack and support it on two jack stands.

Next, locate the filler pipe and drain the fuel tank into an approved container. You may need to use a hand siphon pump for this step. Once the tank is drained, you can proceed to disconnect the filler hose from the tank using a screwdriver.

It is important to work with caution when handling fuel and ensure that the area is well-ventilated. If you are unsure about any steps or feel uncomfortable performing the task, it is recommended to seek assistance from a qualified professional.

Remove the filler hose

To remove the filler hose from a 2002 S10, you will first need to drain the fuel tank into an approved container through the filler pipe. Use a hand siphon pump if necessary.

Next, disconnect the clamp from the filler hose at the tank with a screwdriver and remove the hose. You may need to apply some lubricant to the hose to help it slide off. If the hose is stuck, try lowering the end of the tank that the filler hose is attached to. This will put downward pressure on the filler hose, making it easier to pry off with a screwdriver.

If the hose is still difficult to remove, you can try applying gentle heat with a hairdryer to soften it, but exercise caution when doing this. Alternatively, you can try cutting the hose and clamping a replacement hose onto the larger-diameter end.

Disconnect the cables and hoses

Disconnecting the cables and hoses is a crucial step in replacing the fuel pump of a 2002 S10. Here is a detailed guide on how to do it:

Firstly, locate the fuel pump. It is usually found at the top of the gas tank. To access it, you will need to either drop the fuel tank or lift the truck bed. If you decide to remove the bed, you will need to place the rear axle on jack stands before loosening the bolts holding the bed down.

Once you have access to the fuel pump, the next step is to disconnect all the cables and hoses attached to it. Be very careful during this process, as any mishandling can lead to fuel leaks. Make sure you have a shop rag or a drip pan to catch any fuel that may spill.

Start by identifying the different cables and hoses connected to the fuel pump. These typically include fuel lines, electrical connectors, and wires. Carefully detach each of these connections one by one. Use the appropriate tools, such as screwdrivers or wrenches, to loosen any clamps or fittings holding the hoses and cables in place.

After disconnecting all the hoses and cables, you should be able to carefully remove the fuel pump. Be mindful of any remaining fuel in the lines and try to minimise spillage. Place the removed pump in a safe area, away from any open flames or sparks, as it may still contain residual fuel.

Now that the old fuel pump has been successfully removed, you can prepare to install the new one. Ensure you have the correct replacement pump for your specific 2002 S10 model. It is also important to inspect the fuel lines, hoses, and connectors for any signs of damage or wear. Replace any parts that appear faulty to avoid future issues.

Finally, you can proceed to install the new fuel pump by carefully connecting the cables and hoses. Ensure all connections are secure and tight to prevent leaks. Once the new pump is installed, you can reassemble the truck bed or refasten the fuel tank, depending on your chosen method of access.

Remember, working on the fuel system can be dangerous, so exercise caution and follow safety guidelines. Always work in a well-ventilated area, avoid smoking, and keep away from open flames or heat sources.

Replace the pump

To replace the fuel pump on your 2002 S10, you will need to first park your vehicle on a level surface, with enough room to work around the truck. Next, disconnect the fuel pump relay in the engine compartment. This is located in the fuse/relay box for 1995-1997 2.2L engine models. For other models, you will need to press the small stem inside the Schrader valve, which is located on the fuel inline rail.

Now, disconnect the negative battery cable and raise the rear of the truck with a jack. It is important to safely support the vehicle with jack stands. You will then need to drain the fuel tank into an approved container through the filler pipe. Use a hand siphon pump if necessary.

Disconnect the filler hose from the tank using a screwdriver, and remove the tank shield. Support the fuel tank with a jack and a piece of wood to avoid damage. Remove the tank-holding straps with a ratchet and socket.

Lower the fuel tank and disconnect the fuel lines from the fuel pump/sending unit assembly on top of the tank. Unplug the pump electrical connector.

Now, you can remove the old pump and install the new one. Install a new pump/sending unit O-ring and set the pump assembly in the tank. Lock the assembly lock ring by turning it clockwise until it locks into place.

Reconnect the fuel lines and electrical connector to the sending unit assembly. Reposition and secure the fuel tank with the holding straps. Install the tank shield and connect the filler neck to the tank.

Finally, lower the truck, plug the fuel pump relay, and connect the negative battery cable. Refuel the vehicle, start the engine, and check for any potential leaks.

Parts and Tools

• Approved fuel container
• Ratchet and socket set
• Drift punch and soft hammer
• Jack and jack stands
• Hand siphon pump
• Screwdriver
• Wood block
• New fuel pump

Frequently asked questions