2004 Chevrolet S10 PickupFACTORY OEM SERVICE PROCEDURE

Installation Procedure

    Fig 1: View Of Fuel Sender Assembly Connections (Pick-Up)
    GM54674Courtesy of GENERAL MOTORS CORP.
  1. Install a new O-ring on the modular fuel sender to the tank.
  2. Align the tab on front of the modular sender with slot on front of the retainer snap ring.
  3. Slowly apply pressure to top of the spring loaded sender until the sender aligns flush with retainer on the tank.
    4. IMPORTANT: Ensure that the snap ring is fully seated within the tab slots.
  4. Insert snap ring into designated slots (1).
  5. Connect the fuel sender fuel and EVAP pipes.
  6. Connect the fuel sender electrical connectors.
  7. Connect the negative battery cable.
  8. Inspect for fuel leaks through the following steps:
    1. Turn ON the ignition for 2 seconds.
    2. Turn OFF the ignition for 10 seconds.
    3. Turn ON the ignition.
    4. Inspect for fuel leaks.
  9. Install the pickup box. Refer to Pickup Box Replacement in Body Rear End.
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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