Monday, July 11, 2011

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

    Click image to see an enlarged view

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



    Click image to see an enlarged view

    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.


    ----------

    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.

      Click image to see an enlarged view

      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.
    -----------

    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.

      Click image to see an enlarged view

      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.

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

    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.

      Click image to see an enlarged view

      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



      Click image to see an enlarged view

      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.

        Click image to see an enlarged view

        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.
        =========

        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.


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