99 Chevy Express Savanna Van Fuel Pump through floor cut out access panel 1996-2002

[@edringeling1636]

Thanks for the Tip.Saved me a lot off trouble.Now i can work from the inside warm and dry because my Van is standing outside and it is raining a lot here in Holland during autumn.

[@jammy46235]

It amazes me that it seems like every time your fuel pump goes out it’s when you just filled the tank happened to me twice on different cars 😂

[@xtomkx]

The pumps in that era Chevy vehicles don’t last. If you talk to any owner they will tell you pumps last 80-100k miles.

[@toryrainey6376]

PC

[@DougJohns]

Same as me... I'm watching this video as I am about to do the third one... just after I filled it... it went in the Walmart parking lot just as a snow storm was starting.

[@santisimarisingtv]

This is the most pract I cal way to replace the fuel pump, if you are a brave DIY type of guy. And owned some tools. Some comments here, are not diy friendly so they question your actions. Then you wonder why are they researching on KZbin unless you planning on taking on the job. But this idea is great! You will always have access to the pump. All you need to do is make a cover for the opening. Good job mate and thank you for the Tutorial.

[@flyurway]

The tool to use for cutting the hole is one of those oscillating multi-tools. Use the 1/2 moon blade, it naturally cuts arrow straight, nearly zero chance of sparks, only cuts maybe a 1/2" deep and it cuts a nice, clean, paper thin line. I bought one specifically to do this same job on my '06 Avalanche and it worked like a charm and was one of the best mods I ever did to save a ton of headaches. And if you go to Harbor Freight the tool is as cheap as $20, or opt for the "premium" variable speed version for about $35. It's paid for itself a dozen times by now and so has this modification.

[@tomkuz3689]

Good idea Andork. Multi tool sounds like the way to go.

[@hollywoodthedj1673]

Do you know the name of that oscillating tool you speak of I’m going to harbor freight to find it when I cut the hole in the floor of my 04 Yukon Denali I used the circular saw it was way too many sparks but it got the job done I was nervous tho😂

[@peterrodriguez608]

you saved me awesome i have a box truck wood floor it just made my day

[@dariomendoza191]

way easier and safer than dropping that big old monster you can even have you favorite drink while doing it!!! Thanks for SHARING!!

[@sunnylandcamper]

Sweating balls right meow..a drink is in order. Trying to figure this crap out.

[@santisimarisingtv]

This is an ideal way to go. Specially you dont the ways to work while lifted. You can do this anywhere while the van us on the ground.

[@scoots8519]

With 340,000 on my 2000 chevy van this is how I am going to do it. I had it replaced when the van was newer and it was $700. Just bought the pump online for $58.00.

[@markhopkinsphoto7257]

I am having an issue getting the pump to seat. It's as if the rubber gasket/ORing is too thick. Any tips on getting it to seat all the way down?

[@CR-ny7ep]

IIRC there is a GM service bulletin that says to do exactly this for certain model Cadillac SUVs. Cut a hole in the floor. Probably a good choice on vehicles that have seen salt where the tank attachments may not come apart easily. But be sure to seal the hole well so carbon monoxide can't enter. If you can go to a junkyard and cut a larger piece out of the floor to cover it I would do that.

[@tomkuz3689]

Good point about the Carbon Monoxide. I put the carpet over it and it sealed fine.

[@pedrogarcia6566]

Great video thanks

[@exhilarationaccelerationpo9082]

Hey, got those dimensions ya wanted; 35.5 Inches aft from the Driver's Seat Mount, 20.0 Inches inboard from Filler neck body shroud where it intersects the floor, mark (which falls right on a Bend of the corrugated floor) and drill a 1/4 Inch Hole saw pilot. Don't drill too deep, RIGHT?!! All measured on the inside of a 2000 2500 Express Standard Cargo Van. Tip: You can always make the Hole bigger later but, ya for sure can't make it smaller! I used a 5 inch diameter Hole saw, it's a little tight but, ya don't wanna make the hole really big like the in Video. Turn the Hole saw Backwards for a little while, STOP for lots of cooling time, Turn... STOP again, Turn... STOP again, Turn... STOP again, Turn... STOP again, try turning Forward if the Hole saw grabs too much resume Backward and use Oil! I used a 1 hp. Your Drill motor might not be powerful enough to turn a 5 inch hole saw forward. For finish work, I used a 6 inch Deck cover for a Boat to plug the Hole. The cover unscrews for EZ access images-na.ssl-images-amazon.com/images/I/71kRuhNnFWL._SL1476_.jpg Got on Amazon Yes, I needed to clean up a 1/2 inch all the way around cause, of the sharp Edges and damaged edge which made the Hole a little Bigger but, made a nice clean Job outta my work and also covers where I scratched the paint☺

[@nfergus11]

nice

[@Andy-ue3dv]

Thanks for sharing. 🙏🏻 I might do this on the same express van as you

[@philis52]

@@Andy-ue3dv Your certainly welcome! Glad I could help!

[@Andy-ue3dv]

@@philis52🙏🏻

[@elsecomojado1]

I converted mine, I got wood flooring, net time I replace the floor, I will make a priper access panel. Maybe in about 10 or 15 years. Stay tuned.

[@torrischappell7339]

Did mine to but can't get retainer off

[@dwainekahicks]

There's Usually Enough Room To Squeeze An Angled Pair Of Needle Nose Pliers, Disconnect The Fuel Lines & Wire Tie The Harness Out Of The Way, Then You Can Cut The 2 Long Sides & The Short One @ The Top, Bend It Back, Like An Access Door, Bend Back & Seal With Silicone 💁🏽‍♂️

[@torrischappell7339]

Can I do this to a gmc vandura

[@mongomongo17]

i used a panel cutter on the air hammer

[@JL-oc4pt]

Doing this process now on my 07 gmc same story as soon as we got out their off on the dirt road 6 miles in, my pump went out.

[@daver8895]

Hi there. Good idea. Just filled up and I believe it’s my pump. Can’t drop the tank as I do t want to deal with all that. I’m just curious if you’ve had any drawbacks from cutting out the hole? There has to be a better way to put it back with like hinges or something to prevent water from getting through or up. I have a cargo van so it’s not that big of a deal for me with carpet and all that but still I don’t wanna ruin the thing. Thanks man

[@xtomkx]

Dave R don’t be concerned about having a hole in the floor as it does not affect the van in any way. The video is several years old and I never had any issues. Biggest concern is cutting the hole and staying away from gas lines. Somebody mentioned using a multi tool which will probably work better than sawzal.

[@silentdecay]

Hey there Dave, did you try this out and wondering what technique you might have used if you did? Drawbacks etc? I'm strongly considering same on my cargo van since its dead of winter cold & no garage or even level ground to jack up & drop the tank. So, yeah any added info would be a help / greatly appreciated. (Hope your situation is resolved either way). -J

[@daver8895]

Hey guys. Yes I absolutely did this. However, I just cut three sides with a grinder and peeled it over so when closing it back I wouldn’t have to put any plates to keep it from falling through. I put a piece of sheet metal over the pump from underneath the van to protect the lines from any hits from the grinder. Just remember the rubber carpet needs to be removed or blocked because the underside is highly flammable from the grinder sparks!! Hope this helps. Thanks for the idea! I just modified it to make it a little easier!! Completely resolved the issue however upon further investigation, it looked like my fuse under the hood was loose! Felt like an idiot for not checking it first. No drawbacks. Once it is siliconed when covered back you won’t even know it’s there. This is the best way to change out the pump! Saved myself a good $700 from the mechanic!

[@silentdecay]

@@daver8895 thanks allot for the update and congrats that it worked out!

[@frankcastle1219]

u remind me of Christopher Walken where u from?

[@YoungHeartedSoul]

not to knock down your video which is great but taking down the fuel tank on these vans is super super easy. I've done it twice on my 1996. ive had this van many years and its a job that takes maybe maybe 3 hours taking it easy and stopping to eat. Now mind you, my van is a conversion van which has the rear ac next to the gas tank and its still easy. not nice to hack sheetmetal . cool vid though.

[@tomkuz3689]

Three hours vs one hour to swap the pump if you have access hole. The pumps are known to fail often on these vans.

[@torrischappell7339]

Finally I got my GMC vandura van 1993 with bad fuel pump imma try this

[@torrischappell7339]

1996 gmc vandura mine is conversion van to so can I cut the hole n mine

[@nyc1655]

Yeah take 3 hours while you stuck on the side of the road 😂

[@YoungHeartedSoul]

@@nyc1655 easy peasy, its easier to take that tank down than to curl up tug then glue everything or rivet a plate. Throw an acdelco pump and u will be fine. Throw in an airtex pump and u will be doing this job lots of times.

[@meyawabdulaziz3863]

why haven't the manufacturer though about this ? i mean having to drop the entire tank ...specially when its like full of fuel ?

[@tomkuz3689]

There are cars that have fuel pump access holes from factory. But for most it is another thing they can save money on. Most pumps fail after warranty period so this will fall on the owner to pay dealer for repair.

[@meyawabdulaziz3863]

@@tomkuz3689 yeah im pretty sure cause my 1985 e23 bmw has a hatch on top of the fuel pump assembly so you can access to it ...its a shame not all cars are like that

[@albertoleiva7191]

The only reason the fuel pump goes out cuz everybody likes to run it on empty you should just fill it up when it's at a quarter tank the fuel pump should last you at least 200,000 MI

[@xtomkx]

Obviously you haven't had this van very long. Let us know how it goes for you

[@MM-fh3ml]

the guy is just showing us how to cut a hole in the floor in the right place. The camera is moving so much that I cannot follow... As for replacing the pump through other methods, that is not the topic of this one. The only problem with this is that water will get in through the floor hole and rust.

[@CR7659]

That little bit of hump is the fuel filler neck housing. That is the same in all of the vans. The fuel lines are $150 or so new now. The interchange is a ton of 1996-99 trucks and some through 02.

[@pony69y]

macgiver on cars

[@danb.3397]

A 2 minute vid done in 7 and a half.

[@spawn00x]

Can I get some cowbell with that

[@raybosflorida4928]

COULD HV REPLACED 2 PUMPS IN HALF TIME U EXPLAINED HOW TU CUT A FKN HOLE!! LOL THX

[@xtomkx]

Raybo sflorida you know I'm awesome with my MC giver tricks.

[@rettkowskibrian]

Lol that's what I thought.LOOOONG video on how to cut a hole.lol

[@stefanmeyers2808]

Quit taking drugs and you'll have a longer attention span. If the long vid bothers you, only watch 2 minutes on high speed. duh

[@dannywatts5262]

Yea wat easy

[@williejackson7544]

Pm

[@danb.3397]

OK, good info but about 5 minutes too long.

[@chechygalvarez2269]

Whyyyyy?....you really don't need to do that.

[@alolipa]

So instead of doing it the right way you did it the butcher way