Fuel system parts removal and installation for 2000 Chevy S-10 2.2/4 cylinder?

Removal & Installation

Fuel filter:---

1. Before servicing the vehicle, refer to the Precautions section.
2. Properly relieve the fuel system pressure.
3. Remove or disconnect the following:
   
   
   Negative battery cable

   Fuel filler cap

   Quick connect fittings from the filter

   Filter feed nut and the clamp bolt

   Filter and the clamp from the vehicle
   
   

   

   

   Fig. Fuel filter location along frame rail-2.2L engine

   
   
   

   

   

   Fig. Fuel filter location along frame rail-4.3L engine
   
   

To install:

1. Install or connect the following:
   
   NOTE

   The filter has an arrow (fuel flow direction) on the side of the case, be sure to install it correctly in the system, the with arrow facing away from the fuel tank.
   
   
   
   
   Filter and clamp with the directional arrow facing away from the fuel tank, toward the throttle body
   
   
   
   
   Fuel feed nut

   Filter clamp assembly bolt

   Fuel quick disconnect fittings to the filter

   Fuel filler cap

   Negative battery cable
   
   
2. Check for fuel leaks as follows:
   1. Turn the ignition ON for 2 seconds.
   2. Turn the ignition OFF for 10 seconds.
   3. Turn the ignition ON .
   4. Check for leaks.

   
   

   
   

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   Fuel Level Sending Unit

   Removal & Installation

   
   

   1. Disconnect the negative battery cable.
   2. Properly relieve the fuel system pressure.
   3. Drain the fuel tank.
   4. Remove the fuel tank.
   5. Remove the fuel sender assembly.
   6. Disconnect the fuel pump electrical connector.
   7. Remove the fuel level sensor electrical connector retaining clip, if equipped.
   8. Disconnect the fuel level sensor electrical connector from under the fuel sender cover.
   9. Remove the fuel level sensor retaining clip, if equipped.
   10. Squeeze the locking tangs and remove the fuel level sensor.
       
       
       

       

       Fig. Fuel level sensor (3), sensor retaining clip (4), fuel pump electrical connector (5), fuel level sensor connector retaining clip (6) and connector (7)

   
   

   To install:

   1. Install the fuel level sensor.
   2. Install the fuel level sensor retaining clip.
   3. Connect the fuel level sensor electrical connector.
   4. Connect the fuel level sensor electrical connector retaining clip.
   5. Connect the fuel pump electrical connector.
   6. Install the fuel sender assembly.
   7. Install the fuel tank.
   8. Refill the fuel tank and install the fuel filler cap.
   9. Connect the negative battery cable.

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   Fuel Pressure Regulator

   
   

   Removal & Installation

   
   
   2.2L Engine
   

   1. Properly relieve the fuel system pressure.
   2. Disconnect the negative battery cable.
   3. Remove the pressure regulator vacuum hose.
   4. Remove the pressure regulator attaching screw.
   5. Remove the pressure regulator assembly and the O-ring. Discard the O-ring.
      
      
      

      

      Fig. Fuel pressure regulator location on fuel rail assembly-2.2L engine

   
   

   To install:

   1. Lubricate the new pressure regulator O-ring (3) with clean engine oil, then install the O-rings on the pressure regulator.
   2. Install the pressure regulator assembly (2) onto the fuel rail (4).
   3. Install the pressure regulator attaching screw (1) coated with an appropriate thread-locking material. Tighten the pressure regulator attaching screw to 106 inch lbs. (12 Nm).
   4. Connect the negative battery cable.
   5. Inspect for fuel leaks.
   6. Turn ON the ignition, with the engine OFF for 2 seconds.
   7. Turn OFF the ignition for 10 seconds.
   8. Turn ON the ignition, with the engine OFF.
   9. Inspect for fuel leaks.

   
   

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   Fuel Pump

   
   

   Removal & Installation

   
   
   

   1. Properly relieve the fuel system pressure.
   2. Disconnect the negative battery cable.
   3. Lower the spare tire.
   4. Remove or disconnect the following:
      
      WARNING

      The fuel sender assembly may spring up from the fuel tank. When removing the sender from the fuel tank, keep in mind that the reservoir bucket is full of fuel, so you must tip the sender slightly during removal to avoid damaging the float. Discard the fuel sender O-ring and replace with a new on during installation.
      
      
      
      
      Rear tail lamp assemblies

      Frame-to-pickup box bolts

      Wiring harness ground wire from the frame

      License plate lamp

      Fuel filler neck-to-pickup box ground wire and screws

      Fuel tank on crew cab models

      Pickup box

      Fuel sender electrical connectors

      Fuel sender and Evaporative Emission (EVAP) pipes
      
      
   5. While holding the module fuel sender down, remove the snapring from the designated slots (1) found on the retainer.
      
      
      

      

      Fig. Hold the fuel sender down, and remove the snapring from the designated slots (1) found on the retainer

   
   

   To install:

   1. Install a new O-ring on the fuel sender to the tank.
   2. Align the tab on the front of the sender with the slot on the front of the retainer snapring.
   3. Slowly apply pressure to the top of the spring-loaded sender until it aligns flush with the retainer on the tank.
      
      NOTE

      Make sure that the snapring is properly and fully seated in the tab slots.
      
      
   4. Install or connect the following:
      
      
      Snapring into the proper slots

      Fuel and EVAP pipes

      Electrical connectors

      Negative battery cable
      
      
   5. Check for fuel leaks as follows:
      1. Turn the ignition ON for 2 seconds.
      2. Turn the ignition OFF for 10 seconds.
      3. Turn the ignition ON .
      4. Check for leaks.

      
      
   6. Install or connect the following:
      
      
      Pickup box to the truck

      Filler neck-to-pickup box screws and ground wire

      License plate lamp

      Wiring harness ground wire to the frame

      Frame-to-pickup box bolts and tighten to 52 ft. lbs. (70 Nm)

      Rear tail lamp assemblies
      
      
   7. ---------------

   
   

   Fuel Rail (Supply Manifold) & Injectors

   
   

   Removal & Installation

   
   
   2.2L Engine
   

   1. Relieve the fuel system pressure.
   2. Remove or disconnect the following:
      
      NOTE

      Use a back-up wrench on the fuel rail return fitting to prevent it from turning.
      
      
      
      NOTE

      Because each injector is calibrated for a specific flow rate, make sure you only replace fuel injectors using an IDENTICAL part number to the old injectors.
      
      
      
      
      Negative battery cable

      Intake manifold, if necessary

      Fuel injector electrical connections by pushing in the wire connector clip and gently pulling on the connector

      Fuel feed inlet pipe from the rail
      
      
      
      
      Fuel return pipe from the fuel pressure regulator

      Fuel pressure regulator

      Fuel rail attaching bolts and lift the fuel rail assembly from the cylinder head

      Fuel rail by moving the rail toward the front of the engine

      Fuel injector retaining clip

      Fuel injector
      
      
      
      
      

      

      Fig. Exploded view of a typical fuel injector-2.2L engine

   
   

   To install:

   
   

   NOTE

   When installing the injector care should be taken not to tear or misalign O-rings.

   
   

   1. Lubricate the injector O-ring seals with clean engine oil and install them injector.
   2. Install or connect the following:
      
      NOTE

      Use a back-up wrench on the fuel rail return fitting to prevent it from turning.
      
      
      
      NOTE

      Rotate the fuel injectors as necessary to avoid stretching the wire harness.
      
      
      
      
      Upper O-ring, lower back-up O-ring and lower O-ring

      Fuel injector to the fuel rail

      Fuel injector retaining clip

      Fuel rail and insert it into the cylinder head

      Fuel rail retaining bolts and tighten to 18 ft. lbs. (25 Nm)

      Fuel pressure regulator
      
      
      
      
      Return pipe to the fuel pressure regulator. Tighten the fuel pipe nut to 22 ft. lbs. (30 Nm).

      Fuel feed inlet pipe to rail
      
      
      
      
      Injector electrical connections

      Intake manifold, if removed

      Negative battery cable
      
      
   3. Inspect for leaks as follows:
      1. Turn the switch to the ON position for 2 seconds.
      2. Turn the ignition switch OFF for 10 seconds.
      3. Turn the ignition switch to the ON position and check for leaks.

      
      

      --------------

      Throttle Body

      
      

      Removal & Installation

      
      
      2.2L Engine
      

      1. Disconnect the negative battery cable.
      2. Remove the air cleaner resonator from the throttle body .
      3. Disconnect the electrical connector from the idle air control (IAC) valve.
      4. Disconnect the electrical connector from the throttle position (TP) sensor.
      5. Remove the vacuum hoses at the throttle body.
      6. Remove the accelerator and cruise control cables from the accelerator cable bracket.
      7. Remove the accelerator cable bracket.
      8. Remove the throttle body attaching bolts.
      9. Remove the throttle body from the intake manifold.
         
         
         

         

         Fig. Removing/installing throttle body assembly-2.2L engine

      
      

      To install:

      1. Inspect the throttle body gasket, replace as necessary.
      2. Install the throttle body.
      3. Install the throttle body attaching bolts and tighten to 89 inch lbs. (10 Nm).
      4. Install the accelerator cable bracket .
      5. Install the throttle and cruise control cables to the throttle body.
      6. Install the vacuum hoses to the throttle body.
      7. Connect the electrical connector to IAC sensor.
      8. Connect the electrical connector to TP sensor.
      9. Install the air cleaner resonator to the throttle body.
      10. With the engine OFF, check to see that the accelerator pedal is free, by depressing the pedal to the floor and releasing.
      11. Connect the negative battery cable.
      12. Reset IAC valve pintle position:
          1. Turn ON the ignition, with the engine OFF.
          2. Turn OFF the ignition for 10 seconds.
          3. Start the engine and inspect for proper idle and throttle operation.

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          Relieving Fuel System Pressure

          
          

          The fuel systems operate under high fuel pressures. It is very important that the pressure be properly relieved prior to servicing the system or any of its components.

          A Schrader valve is provided on these fuel systems to conveniently test or release the system pressure. A fuel pressure gauge and adapter will be necessary to connect the gauge to the fitting. Most of the MFI systems utilize a service valve on one end of the fuel rail assembly.

          1. Before servicing the vehicle, refer to the Precautions section.
          2. Disconnect the negative battery cable to assure the prevention of fuel spillage if the ignition switch is accidentally turned ON while a fitting is still detached.
          3. Loosen the fuel filler cap to release the fuel tank pressure.
          4. Be sure the release valve on the fuel gauge is closed, then connect the fuel gauge to the pressure fitting located on the inlet fuel pipe fitting.
             
             CAUTION

             When connecting the gauge to the fitting, be sure to wrap a rag around the fitting to avoid spillage. After repairs, place the rag in an approved container.
             
             
          5. Install the bleed hose portion of the fuel gauge assembly into an approved container, then open the gauge release valve and bleed the fuel pressure from the system.
          6. When the gauge is removed, be sure to open the bleed valve and drain all fuel from the gauge assembly.
          7. When fuel service is finished, tighten the fuel filler cap and connect the negative battery cable.