Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2004 Chevrolet S10 PickupFACTORY OEM SERVICE PROCEDURE
Installation Procedure
- Install the fuel sender into the fuel tank. Refer to Fuel Sender Assembly Replacement (Utility/Crew Cab) or Fuel Sender Assembly Replacement (Pick-Up) .
- Install the fuel tank insulators.
- With the aid of an assistant, position and support the fuel tank.
- Raise the fuel tank.
- Connect the fuel feed pipe, the fuel return pipe, and the EVAP pipe at the fuel sender.
- Connect the fuel pressure sensor and the fuel sender electrical connectors.
- Connect the EVAP pipe to the rollover valve.
Factory Service Tools
Use the Manual With the Right Hardware
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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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