2003 Chevrolet S10 ZR2 Fuel Pump Replacement 4.3L V6
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- เผยแพร่เมื่อ 14 ต.ค. 2024
- This video shows how to diagnose and replace a fuel pump for a 2003 Chevy S10 with the 4.3L V6. Designed for home users who don't have access to a lift using only basic hand tools and a jack / jack stands.
This repair at the dealership can cost $800-$900 (the dealer wanted over $600 for a replacement Delco pump assembly not including labor to install) but the total cost to replace the pump via the rebuild kit was approximately $42 plus around 2-3 hours of labor (which included making the video). Enjoy - hope you find it useful.
This is the first video I've posted and I used a old, cheap Flip Mino HD camera held in one hand so I apologize in advance for this not being high production quality.
Note there is a cameo from my shop assistant around the 33:00 minute mark.
![Chevy S10 Fuel Pump Replace [How To]](/img/n.gif)
Absolutely fantastic tutorial. Thanks so much
I have a 97 Chevy S-10 and don't need a fuel pump...yet. The only thing that is new on this truck is the long block and I just changed out all of the sensors. But it is time for everything to start going out, but after viewing your tutorial I am saving this video! Good Job!
thanks for your video. it was very cold evening and after leaving the gym my sonoma didn't start. it cranked but didn't stayed on. I followed your first step and problem solved I guess it was just the relay. after 30 min stranded, found your video. thanks.
That's awesome - much better to have it be a simple relay and not the pump itself. Hope a replacement solves your problem for good.
I've got a 2001 s-10 4.3 engine. Fuel pump went bad and I got a new one on e-bay for 36 bucks with the fuel gauge included. That was about 18 months ago. I took all the bolts out of the bed and lifted the bed up on just one side over the fuel tank. Used a 4x4 to hold the bed up. I had a little trouble clearing the fuel neck as I jacked up the corner but not much. No damage to anything. My biggest problem was trying to install the new o-ring. It was round and the old one was flatter. After about 20 minutes I just reinstalled the old ring. No worries.
Excellent tutorial. Probably one of the best ones I've seen for this procedure. Thank you.
I'm so choked...about 3 years ago spent $1,300 to have this repair done and could've done it myself. The video was great! The detailed explanations are appreciated as not everyone knows all the little details that come in handy. The thought of dropping the tank is what always took this job out of my capability level...now I feel confident I could do it. And I might have to...the last repair was on my ex's truck. I'm seeing someone else now driving the same type of truck but hasn't had the pump changed yet. Thanks man!
Thanks - hopefully you'll never need to do this, but if you do I hope it helps. These trucks are getting older so repairs seem more frequent these days. I'm just hoping I don't need to do this one again anytime soon.
Jesus 1400 what the hell Why? Did they replace all the lines and tank????? I spent 400 at my mechanic I didn't want to dick with it.
@@sschevmale24 I wish I had your mechanic. Seems like every mechanic I go to I come out with it high price
@tomtroy3792 he just unbolted bed propped up piece of wood on jack and had enough room to remove pump. Might be 500-600 today with inflation
Wow! What an awesome video! Thank you so much for doing this... you have no idea how helpful this is. I really appreciate the detail and thoroughness, good camera shots at points of concern, and easy to follow explanations. This video is close to a 5-star polished presentation; hard to believe this is your first post. Although it was only a few seconds, the cameo of your assistant was icing on the cake.. too precious! You made my day... thanks again, Phormify!
Helpful video, thank you. Will have this on standby when doing mine today. I wish I had known about rebuild kits earlier, and had time to wait on shipping, would have saved me a lot of money.
This really really help me on the same project for a ZR2. because the previous owner changed the pump with other kind of aftermarket. and no one has the replacement for my blazer. so i watched your video and i purchase the same model as you shows on this video. and the store guy says that this actually it's the zr2 4.3 pump... so.. the other thing is that the black hose was not connected to anything , and again with this video i actually know where this hose goes.
thank you
Glad it helped you - sounds like you figured everything out and probably saved some cash in the process.
Yes sir, this video show me how to put back the original pump. I compared the replacement number and it was right. It's a hard work to pull down the tank. the weather is so hot... :( .
Great video. To the point and without the b.s. that others go off the subject.
Thank you!
Thanks a lot for this video. It made my life easier. I liked how you explained how to remove the tank bed. Just a little tip I used a goose neck attachment and an extension to get at those back bolts. I did leave my tailgate on and had no problems raising my truck bed. Great Job explaining how to repair the fuel pump. Unfortunately I had to spend 300 bucks on the entire assembly but found your recommendation helpful.
I'm with you, I ended up running to the auto parts store for a new unit once we pulled the old one and discovered/decided the rebuilt kit really wasn't our best option. Still, it was this detailed video that made the whole process so simple, almost seamless. Really we encountered no real hangups other than one stubborn bolt under the bed.
really great video bud. as far as diy tutorials go, this is 5 stars. really appreciate the thuroughness
Thanks for the feedback - I hope you have great success with yours!
Good video, and very well explained. I would just like to add that saving some money is great by ordering just the rebuild kit, but a known issue with the factory pump assembly is the sending unit malfunctioning, as it did on my 2001 S-10. I just had mine replaced by my mechanic that did the same procedure as you. He just jacked up the bed and replaced it that way. My sending unit had been intermittent for a few years, but I was going to wait until the fuel pump itself actually went bad. Sometimes the gauge wouldn't read correctly, it would drop down to "E" while sitting still, then jump back up after driving, etc. In my opinion, it's just best to replace the whole assembly and spend the $250 or so, and be done with it. Hopefully you will not have any issues with your sending unit to where you have to go through this same procedure again. Thanks again for the great video!!
Sometimes when you think you're sending unit is going bad , it's the stepper motor in your dash Guage cluster, just a bit of information in case anyone else has gas needle issues.
Nice work on this video. I'm saving this one for future reference pictures.
I did this job on my 03 ZR2 (nice truck BTW) without lifting the bed. Did it all from underneath. My pump hadn't died so I was able to run all but about 1/2 gallon out of the tank. There were difficult moments mostly caused by the fact that this fuel tank assembly is installed into the chassis from the top at the assembly line so some of the clamps were more difficult to get to than that needed to be but it went back together easy. Mine has a plastic tank and had very little fuel it so it was easy to handle. No jacking and no sticking my head and arms in giant mouse trap. If I had to do it again I would still do it that way but it's just personal preference. Plus my clamps and fasteners are all facing easy access directions now.
Well done video! Extremely thorough! You just made my job way easier and way cheaper than alternatives. I've dropped a tank before and it sucks. Connecting hoses back up is always the hardest. Was nice to see what ill get into by lifting the bed. I didnt want to spend $300 on a whole new pump assembly, and didnt know of the rebuild kit. most places dont even carry them or even know about them. Ive got my rebuild kit on order from Amazon using your parts number in the video. $35! You made my project simple. Thanks man!
Glad it was helpful - and glad you could save some cash! Best of luck on your install.
Very good video! I'm glad you go into so much detail. Thanks
Thanks for posting. I need to replace my fuel guage, so I am thinking of a complete assembly.
+onemon22 ..yep,... shop online for great prices
Great information very helpful I just had to do mine on my s10 and this info. worked great thank you very much for making it a lot easier for me.
Just changed my fuel filter as well but just got same rebuild kit in today didn't take too long to get it in thanks again!
Awesome thanks sir. Going to give it a shot, pep boys wanted to charge over 900 to do this
Well done video and Thank you. One thought,, if the frame mounted fuel filter is accessable with the bed up wouldn't it make sense to go ahead and change it rather than have to crawl around on your back to change it later?
the sending units usually fail first. complete pumps aftermarket start at $40. AC/Delco /OEM start at $135. Bosch upgrade pump $140-$145 pump Sending units $35. Delco pump kits are indeed $40 @ Amaz ...
Thanks for the video.
thank you very much for your time and video 👍🏽
very informative and i was dreading dropping the fuel tank so thanks great video and excellent job recording
Thanks!
same man i got a 1990 4.3 v6 i wasn't wanting to pull the bed completely off
Best video on this thank u
joe30725 Glad you liked it and hope it works out for you. I didn't mention it in the video, but also a good idea to replace fuel filter at the same time. Mine was almost new so I skipped that step (and therefore didn't film it).
I never had any luck just rebuilding pump. 3 weeks after rebuilding it failed then rebuilt again and 5 months it failed again so this time I bought the whole unit and success as it is still working 82,000 miles later. Cost was 275 bucks at carquest as it was the only store in my area that had one
On the rear bed bolts if you do not have a hitch there is a hole in the frame for a socket and extension to get through. A breaker bar works well to lossen bolts too. That is what I used.
good video. just ordered a rebuild kit from mainland china for $15. crossing my fingers.
Great video. Thank you.
Very nice video. Thank you very much.
It is easier to get the 4th bolt without a hitch in the way making the 3rd bolt the hardest to get out. I found on mine that it was handy to have different length sockets and extenders. On my 94 s10 I took the bed off stood it up on the front and was able to undercoat the frame and bed. I also installed a hitch off a 96 blazer that isn't in the way like this one is but I had to squeeze the frame 1/8" to get the hitch on it and the factory bumper wont fit without modifying it to clear the receiver.
I did my 2003 ZR2 FP from the bottom but I had almost all gas out. (notice you have 5/8 full). It was at moments difficult but I had large tool box in bed with 2nd battery in it so didn't want to go that way. I bought Delphi pump complete assy from RockAuto.com for $200. They have a few choices even cheaper but Delphi is OEM equivalent. I would never do the rebuild kit because of all the work to get FP in and out but it is a more cost effective choice. Nice looking in white. Mine's silver but paint has held up well. Well done video.
Dropping the tank isn't really anymore work if you have to deal with a tool box or a full box so sounds like you made a wise decision. I also agree buying the full assembly is the way to go for many people and can avoid having to redo the repair in the future so it can be cheap insurance.
Delphi sux. I had to replace mine after 40,000 miles ......
@@sschevmale24 Well, that's disappointing to hear. They are pricey little B*st*rds and a bit of a hassle to get to also.
@@x-man5056 maybe you will have better luck man. Try good gas and fuel treatments. I think I got Borg Warner now I cant remember !!!!!
@@sschevmale24 4 times a year with injector cleaner. Do you have metal tank or plastic?
Awesome video my man! Quick question for ya. I have same truck but 4 door. Is it still possible to tilt truck bed or do I need to pull tank from bottom? Looks like it’s more under cab than the bed. Thanks!
Will Unmisig - Sorry I really have zero experience with the four door. You might check to see if there is an access panel under the rear seat as that is fairly common in cars - so maybe you would get lucky and find something under the carpet. Otherwise if it looks like the tank is under the cab rather than the bed you might have to do it the old fashioned way and drop the tank. It can take a little longer and requires you to drain the tank before starting but it isn’t that bad.
Red Pushpin thank you for the response. After reading it looks like I’m forced to do the old fashioned way.
Great job an thanks for the video.
what brand fuel pump is the best?Or they all the same?I had to replace 2 pumps on my sonoma gmc crazzy good work sir.
what a great video!! thanks for awesome instructional tutorial... it's going to really help me tremendously!
Thanks - I really should do more of these.... people still seem to enjoy keeping these S-10s on the road.
Its so nice to actually have someone explain this clearly and with such detail... Many of the other videos I found have a lot of cussing (which I hate) and unclear information. Thanks again Phormify!!!
You bet! And that is why I made the video in the first place because when I looked I couldn't find one that showed me all the detail I wanted. There are some good videos out there but most only cover a small portion of the project or skip details I wanted to know about.
I probably made the video too long and boring - but hopefully it has enough detail that would convince someone who is on the fence about doing the project themselves that they could handle it. After all - I am not a mechanic and don't even bother to change my own oil most of the time. But this was an relatively easy project and saved he hundreds from letting a shop do it.
Best of luck on your replacement - hope it goes as smooth for you as it did for me.
Phormify Do you happen to know if that same repair kit will work with a 1996 Chevy S-10?
Danny Herrera I think so, but any kit you buy should give you the year ranges it covers. Better check that to be sure.
asome i did that way, much easy, thanks!
Thanks for the video ... 'cept for the color and the remote start, I have the exact same truck, and I'm about to use your video to guide me through the steps. Your video is from about a year and a half ago ... I'm having trouble locating that ACDelco rebuild kit using the numbers on your part box. Where did you locate one to order?
I actually got mine on eBay at the time. However you could inquire at sites like Rockauto.com or other online sources known to have large inventories - some have even used Amazon. Worst case you can always go for the EOM kit but it would cost a bit more.
I got one on eBay - $34
However when we pulled the unit, the plastic housing on top broke off at one of the fuel line connections, and taking the time to rebuild the thing not knowing if we could successfully clamp the hose back on the broken part ... well, I decided to run down to the local auto parts store and buy a whole new sending unit - $289
Had I found time, or knew in advance, (although it seems the original OEM part is now discontinued) I found and should have ordered a compatible ACDelco unit at rockauto for a lot less ... but in the long run, when the truck is already apart and occupied in someone else's spot in the garage - time becomes more valuable than money. The Precision unit I got does come with a lifetime warranty.
Thanks for the video, your tips made the whole process very, very easy overall. I may have spent $300 on a part and gave my buddy $100 for his mechanical assistance and help ... but it sure beats the $1100 quote the local Chevy dealer gave me ($472 part, $500 labor, shop fees, tax ... )!!!
I know this is an older video...but, just wanted to say, I sure miss my 2001 Chevy S-10 ZR2...so much fun! Have you seen the new 2017 Chevy Colorado ZR2?
Chris DIYer No I didn't know they were doing a newer ZR2 but I'll have to check it out! I've been thinking about trading so maybe it is time.
The new ZR2s are super nice but also very expensive compared to the S10s. Beautiful machines though.
@@Phormify don't do it man. Keep it. Trust me you will regret it. That's why I still have my s10 278k miles 1996
Hi I know this is an old video so I'm not sure if you still respond to these. My husband bought this exact kit for his 2003 Chevy Blazer S10 - just waiting for it to be delivered. How long did your repair end up lasting? We are on a tight budget and couldnt afford the 200+ for the whole new unit. Thanks for the video!
Stephanie Barry - I still have the truck and haven’t had any other problems with the fuel pump so the repair has held up extremely well. Hope it works as well for you and that it gives you years of worry-free use.
good job on video I learned a lot
Thank you for the video I am Pedro flores I like
Good video man!
Next time what ever side you plan to tip the bed towards leave two bolts in but loosen them 1/4" and let the bed pivot on them like a hinge. That also keeps the bed aligned and keeps the bed on the frame in case it wants to slip off.
Grinding and welding over a fuel tank .
Thanks a lot, really good video
I PLAN ON CONSTRUCTING A DOOR IN MY BED TO ACCESS THE FUEL PUMP ; HAVE LOOK AND OPERATE LUKE A GAS DOOR ONLY WITH A SEAL.
when you checked for voltage in the fuel pump wiring harness where did you ground it ,, to the frame or the wiring harness ,,,,because i'm not getting a ground in the harness on the thicker wire but i am on the thinner black one the grey wire is hot on key turn and crank, my tank is plastic with no wires and i did not raise bed to do my crew cab obviously so only the harness was changed ,grey to grey,, thin blk to thn blk,,, purp to purp ,,and thk blk to thk blkstill my new pump has notn is it possibly junk??
Pretty sure I grounded to the frame but it's been a while.
thank you
as i was driving my truck around town i noticed it wanted to stall.my rpm's went down on a red light or stop sign.then on the highway it was jerking as if it wanted to stall a few times.do you think its my fuel pump?i did notice it does that when i press on the gas.then i stopped at store i had to start my truck 3 times for it to run.can it be my spark plugs and cables?or the fuel pump?any ideas will be greatly appreciated.
Hugo Chavez It sure sounds like the fuel pump is on the way out. When mine started there were a few times the truck didn't want to start right away. It would also seem like it was starved for fuel every now and then. However there is no guarantee as those symptoms could be related to several other things. Best thing to do is test the fuel pump pressure and see if it reads low.
Thank you
Parts are getting hard to find. Thanks great vid.
Amazon.......just got the whole replacement fuel pump assembly for my 02 zr2 for $45.
Rock autos got everything
What sized are the tires and ring? I wish someone could tell me about it
will this work on tippin the bed of a 2000 s10 and are there bushings and how do you line it back up when you bring it back down
+James Abbott Should work the same on a 2000 as they are the same model and share the same bed (slight differences if you have a regular cab vs. extended cab but the process is the same). There aren't any bushings to worry about and assuming you don't remove the rear bolts and just loosen them the bed will drop right back down to where it was. The holes in the frame have a bit of play to allow for some adjustments and you can just nudge the bed back and forth a bit to line them up if necessary.
thanx
Could you remove all the bolts and slide the bed back a foot or two?
That would require a bit more work to disconnect all of the wiring that is attached to the bed - so in the long run it would take a lot more time to try and do it that way.
Side tilt method offers many advantages. We have taken it one step further to invent a BedliftR tool that attaches to the frame and allows one single person to easily and SAFELY do fuel pump work on trucks with a side tilt method. You can watch video at www.tec-tools.com/home.html. It is shown on a lift, but the work can be done on the ground as well. We are just going out to market now, so if you ever were interested in getting a demo model to test out, contact us. Thanks.
Tec-Tools.com would love that
Side tilt will allow for more access and room to work, but how much do you risk bending/buckling the bedside? Tilting back seems to be a better way for stability and to bring it back down for realignment of bolt holes. I read today about someone who used the side tilt method(working alone), buckled their bedside, AND pinched/damaged the filler tube on the way back down.
$22 fuel pump I bought on ebay. Putting it on now and crossing fingers....
Please tell me were online you got your fuel pump please .I needed it like yesterday please .I hate Walking
I ordered my pump from a source on eBay... the parts stores were all way, way more expensive.
sure a lot easier lifting the bed than taking the tank down, gravity kills you when lying under the truck!
I went into a row of potholes at 25 mph, the road was covered with holes and bumps. all my light in the dash flashed, and my engine stopped working, I pulled over, everything was working battery wise, engine was cranking but no start and I wasn't hearing the fuel pump kicking in. I have all the symptoms of a bad fuel pump but my gas gauge doesn't work like yours. I have checked my fuel pump fuse, its fine. Could it be a bad fuel pump ground then ?
Sounds like an electrical failure of some sort. Could be a bad ground but if all the lights flashed it makes me think you might have other issues. You could hook up a fuel pressure gauge and see if you are getting fuel pressure when you crank the engine. If you aren't... you might be on to something so time to dig deeper. If the pressure ends up reading ok at least you eliminated the pump as the source of the problem.
I done that but no fuel pressure when I'm cranking the engine. its really weird!!! today I also notice that the shifter light in the dash (P, R, N, D, 3, 2, 1) doesn't work anymore. I see for exemple, the letters and the numbers, but I don't see if I'm in P, R, or N, or D.
Sounds like you may have a larger electrical problem. Could be more complex to troubleshoot but it may be a gamble to replace the pump unless you’re sure.
Did you notice that when you first turned on the ignition key and tried to start the truck the fuel gauge needle slammed all the way to the left to the "E" And after you made the repairs it didn't move at all.
Henry Avery I guess I didn't notice. Not sure that would be a diagnostic test or not... it might have simply been due to a lack of fuel pressure initially. However the fuel level sensor wasn't replaced so not really sure what it would mean either way.
You might have stepper motor issues in your dash cluster.
where did you go online to order the rebuild kit?
Got mine on eBay but they are available on several websites. Just search for the part number and you'll find distributors.
AC Delco on ebay; $110.00, no shipping. After watching the entire video and getting mine out, I realized, I didn't really need the whole assembly. Could have done it your way, (with just pump).
If you get kroll/kroil to spray on your bolts it's a 100x better than bolt buster
changed mine now it won't start? how much gas did u have
Bobby Brandenburg my tank was about half full I think. Yet another reason I didn't want to drop the tank to replace the pump.
Who in GM had the great idea to put the fuel pressure port near the ignition wires...?
i have a 2003 Sonoma ZR2 and got a new pump for $65.00 on Rock Auto
I bought a lifetime guaranteed pump assembly for 36.00 delivered from ebay
Great video, helped a lot. I purchased a new fuel tank sending unit O-ring from amazon. ACD # G30, GM#15034832, UPC# 021625438214. It fit perfectly, my application was on a 2003 GMC Sonoma 4.3L. Cost was about 10 dollars.
+LeRoy Earley Awesome - glad it helped.
Installed new fuel pump but now gas gage don't work
If it worked before you replaced the pump I have to assume you might have a bad connection that presented itself when you disconnected and reconnected the sending unit. If you just replaced the pump itself and not the entire assembly, I suppose it is possible the sending unit is bad - or when you dropped the unit back into the tank the float might have become stuck. Hopefully you didn't put the bed back on yet so you can try a few things!
great video man and it must be high cost living where u live bro I work at O'Reillys here in Mississippi but very great video best one yet but was ur truck starting and idling rough before it wouldn't crank? n I bought the whole assembly n all for $81 from rockauto.com :)
My situation was a bit odd. One time the truck wouldn't start and I really didn't know what it was but the next day I went to start it and it was just fine. A few days after that it was parked in the garage and would crank and crank but never actually fire. So I guess I was lucky that it died in the garage rather than on the side of the highway. Other than that the pump never gave me any issues so there weren't any warning signs.
@@Phormify Had a fuel pump die on me at the gas station after I filled up the tank and it was a 30 gallon fuel tank.
Got my pump off eBay for $42 I just have to take the pressure sensor off the old pump put on it.
$160 pump new at Autozone....... Crossing my fingers as well
I know this is an older informative video, but man you can yap!
Not denying that - I've got a lot on my mind and there is no off position on the genius switch. lol
Put this back together mister.
Rockauto.com I just bought a fuel pump for $88. they have the same ones you can find at autozone or o'reilly's for $178
I'm a big fan of rockauto, but be careful with the off brand parts, especially if listed under the economy category.
AutoZone carried one I saw for under $200, but the warranty is for only 1 year - I spent a little more and got one with a lifetime warranty. Still, I wish I had more time to research and find one online for less, but truck was already apart and old pump removed when we discovered that using the rebuild kit just wasn't an option!
Can buy the whole unit for about a 100 bucks on eBay
anazon
ac delco 117
knock off 60
THE WHOLE TIME EXPLAINING HOW TO LIFT BED DANGEROUS WAY BY THE WAY
Nothing about lifting the bed is dangerous if you take the proper precautions and take your time. Working on cars - especially the fuel system - can be dangerous but that is why we prepare and learn before ever turning a wrench.
What type is the AC Delco fuel pump you used? jaduranjr at icloud
I don't recall since it was nearly four years ago. However I just searched for compatible parts and found one on eBay if memory serves correctly.
Didn’t show putting the lock ring back on which is difficult. So thumbs down
A BIT TOO MUCH TALKING AND NOT ENOUGH DOING...
Hate that all these parts come from China now , but it works so hats off , I would replace entire assembly because some of the manufacturers build them here.
How many miles were on your truck when the pump went?
Great question - it was so long ago I can't be 100% sure but I believe the truck had around 125,000 miles at the time. I wasn't the first owner so I can't say if it was the original fuel pump although based upon the condition of the pump and rust on the fasteners etc. I believe it was the factory pump. I believe these pumps should last at least 100k, so having 125k on the truck seems about right.
@@Phormify Ok thanks. I bought my 94 s10 new in July of 94 and my truck has 172,000 miles so I guess I am on borrowed time. Not looking forward to that work when it goes bad.