Astro Van Fuel Pump Replacement - 1996-2005 (GMC Safari) - 4 MINUTE DIY VIDEO

NOTE: For some reason some models have an additional cover over the gas tank.
Mine didn’t, many don’t.
If you find a cover on yours you can drop the tank and removed the cover, then next time you replace the fuel pump (there will be a next time lol) you will have the through the floor access you need.
How to drop the tank:
• How to replace a fuel ...
Or you can take a look at this guys video about how he cut through the second cover.
Cutting the second cover open:
• SAFARI FUEL PUMP REPLA...
Be careful, this cover is very close to the lines and wiring. Depending how you cut it you could end up cutting the wires or the fuel lines.
This guy accidentally cut his, in his video he replaced the wires he cut:
• Astro Van 98 Fuel Pump...
This video shows how I replaced my second generation (1996-2005) Chevy Astro Passenger Van Fuel Pump.
The story: I returned to the parking lot after shopping and my 2000 Astro Van just wouldn’t start. I knew from past experience with Astro Vans that when they crank but don’t start, its often that the fuel pump has gone out. I tested the fuel pressure after replacing the fuel filter and only got 10 PSI not enough to start the engine (50PSI). Because I was in a parking lot of a shopping center with security driving around and keeping an eye on me as they saw me trying to start my van, I didn’t feel like dropping the gas tank right there in the parking spot. I also didn’t feel like having my car towed to a shop or my home 80 miles away. So I decided to replace the fuel pump right through the floor of my van without anyone knowing that I was even working on my car. Now this is not an accepted method of replacing the fuel pump, your experience might be different but if you were intending to do something like this I hope you find the video informative :)
Thanks for all your support, I am still trying to get enough subscribers so that amazon will let me into their affiliate program so if you can subscribe it would mean so much! I make videos at least once a week and would love to make more! The work was performed on my 2000 Chevy Astro Van but yours will be very similar!
Now when you use these amazon links you support this channel! It doesn't cost you anything extra, but a small portion of your purchases goes to me when using these links and helps me to continue making more videos!
Tools:
Shop towels or lint-free paper towels
Gloves
goggles
fire extinguisher
gas can (optional)
non-ferrous mallet and punch
wire crimpers/cutter
needle nose pliers
vise grip pliers
18 GA aviation snips
magnet tool
Parts:
1 Delphi EFG0288 Fuel Pump or equivalent
Here is the link to the Fuel Pump used in the video:
amzn.to/2iPpjoF
I am very excited to set a new subscriber goal for this fall! I hope we can reach a very ambitious 800 subscribers by the end of December. Thanks so much to everyone who as been sharing my videos and helping get the word out about how you can save money, learn new skills and be self sufficient using the power of the internet and you!
More videos to come soon!
luke As an Amazon Associate I earn from qualifying purchases.

[@stellabella8224]

You help people with older cars, vans etc. We need guys like you on KZbin.

[@nxne75]

You mention there are links to be found in the description as to what the dimensions/location is for cutting the hole but they’re not listed. Where/what are they?

[@41309c]

Worked like a charm. Perfect detail instructions. Thank you, very much appreciated.

[@MINUTEDIYVIDEOS]

I’m really glad to hear that! Thanks so much :)

[@dariomendoza191]

Bastards car manufaturers they make it as HARD as possible for the little man!! thanks for SHARING!!!!!

[@iplaypearldrums7935]

Corvettes, water pumps' a biatch 🤬

[@tyroneburnssr.9649]

i've done a similar process on my S-10/S-15 trucks and my full size Chevy trucks. saves a lot of aggravation when you have no acces to a rack or lift.or jack-stands and jack that will get you high enough to drop the damn tank. i pop-rivit 3 or 4 1 1/2 in. metal strips to the cut edges with half of the strip showing, that way i something to secure the flap/lid cutout back in place. i usually place a thin bead od silicone in the remaining gap to hlp seal out fumes, dirt moisture, and cover that with a couple layers of aluminum rfeigeration tape, then throw a bed-mat or board over it wide enough to spread the weight of anything that may get thrown on top!!

[@waynegambrell7095]

Like video but makes more sense to just drop the tank. I have done 2 of these jobs by myself and getting ready to do another one on a 97 Astro in the next week. At least you got a hole for the next one. Love it !!

[@pppp-zf5ts]

did a tank drop today on mine actually, took prob 12-15 minutes to drop it, much easier, and no 12x12 hole in the floor

[@transitionindustries1127]

Great idea. I’ll source another Van floor to cut a larger price to put over top the hole and rivet on with some silicone 👌

[@commonman80]

Unorthodox? Are you kidding Me? That's BY FAR THE BEST WAY TO GO... Volvo's are designed to take The Fuel Pump Out JUST LIKE THAT... All you have to do is Remove The Back Seat? AND BAM!!! THERE IT IS... I Think GM Just Designed It The Drop Tank Way to make money on The Labor when it's time to replace it.. All you need now in a metal plate and 4 screws about 1/2 inch long, And you'll never have to worry about Dropping the tank to work on The Fuel Pump.. OR? Clean The Fuel Tank if need be... Good Work.. Great Video... Thanks...

[@NavigatedChaos]

I mean yea it's a great video, no one's talking about the massive fucking hole you left in the van

[@jeanmichelmailhot]

You just saved me 300$ at the shop, thanks !!!

[@karenmay5240]

After you snip the hole , you can lower the tank slightly, just enough to ease out the thin (like a tin can) metal pump cover if it has one. Or you can snip the cover in half , bend and lift it out.

[@malachigreenidge]

great video, thanx, very helpful. Did you forget to replace the rubber O-ring that seals tge pump in? i saw it dangling in the one you took out, but didnt see one on the replacement pump you put in... how important is that gasket?

[@Jacob-hr2vf]

What are the dimensions and where should we drill down at?

[@jameshustis6389]

Where's the round gasket? It goes between the pump and flange? Hope yours didn't leak.

[@AnthonyZbierajewski]

What brand of tin snips did you use? I have the exact same project now.

[@meyawabdulaziz3863]

it worked then died later 2 days later benched tested the pump it works checked the connectors on the van no power is there a an inertia switch ? reset switch for the fuel pump ? ( mine did come from an accident ( front end accident )

[@tormado]

That's one way to do it! rather than wrecking the resale value and workability of the van, I think I'll be dropping the tank 😔

[@RollingCajunOutdoors]

How are you wrecking the resale value? you can literally push the metal back down and screw some straps across the seams to bind it back in place and then throw the carpet back over and no one would even know it existed. No one says you have to cut the 4th side of the hole. The entire reason only 3 sides are cut and it's folded is so that you can fold it back in place. Changes nothing about the van.

[@jefftaylor844]

Actually, the next owner should be happy that the pump is easily and quickly accessible in case another new pump is required in the future. I'd call it value added actually.

[@xxskitsxx15]

​@@jefftaylor844exactly it's a handy thing to have I cut mine and have a piece of sheet metal to cover it with some self tappers then I cover it with a floor mat

[@s10-Mike]

Now Astros and safari vans are rarely seen and old has hell. When my mom drove hers back in the day id live to have seen her face if I just started cutting up the floor lol. I could understand if it was a problem vehicle but these have 2 bolts and the 3 in the gas cap and that's it unless u wanna pinch 2 plastic gas line clips and bring it on the ground. And that was clean i could see it in the salt states now that they are 25 plus yrs old when the bolts are ao rusted they just rip out a rusty chunk of metal with it. Also noticed all the pressure still in the gas line g.d this made my night I could not stop laughing.

[@genemccormick3935]

I wonder if a sheet metal nibbler cutter would over tin cutters ???

[@danielslock]

Great Job man . The only thing i do not like is the way you cut out the plate but all together there is a Big $ saving . Thanks

[@tgipson20]

Nightmare ring is right!!

[@russelltech7691]

Excellent video. Work's like a charm 👍

[@bensmac5361]

Great video! I'm assuming doing it this way is to avoid having to remove the gas tank? - which I'm assuming is a far more difficult way to do it. Thanks for posting this

[@johnnymax6245]

you needed a set of green snips...reds do left angles, greens do right angles

[@PantysniferLee]

Your video is the best way shown for replacing fuel pump in astro van. But how did you fix hole in the floor of van?

[@stopcensoringme6481]

New vent or try buffing it out

[@obijuankenobi6565]

Duct tape and bubblegum

[@regarry10]

This may be faster but it is sure not the best, if you can't fix it right have a professional do it!!!! Don't destroy your floor.

[@sscbkr48]

If the access port is well done it could be value added, but how many pumps are you replacing! Preventative maintenance might be better.. keep your pump cool, don't run with low fuel and annually change your fuel filter.

[@dtlastraightahead2133]

will this work on a 97 Ford Aerostar? some videos show structural frame is in the way certain vehicles

[@tgipson20]

That goddamn locking ring is making me insane

[@Simsanchez]

How you cover the hole afterwards?

[@ajp000000]

Get a piece of sheet metal slightly larger and screw it over it I would also recommend a little rtv around the edge to prevent moisture from coming in

[@Moe_510]

That's you to be the author of the work

[@commonman80]

This Goes To Show That General Mothers Is Full Of Crap.. I CAN NOT For The Life Of Me, Figure Out Why GM Didn't Just Put A Door Or Plate Over The Fuel Pump.. It Would Make Life So Much Easier.. Instead Of Taking Everything Apart And Dropping The Fuel Tank. And? Replacing The Fuel Tank.. Incredible.. Wow.. Anyway? Good Work.. Great Video...

[@mordecaimorris6827]

So do you put a separate piece of metal to cover the hole

[@brofessormex]

This metal is razor sharp. Be very careful with this metal. And yes a wheel would be a fire hazard. Thats an industrial can opener.

[@podium918]

Where is this location I got a bunch of crap in the way and would rather cut right over it

[@randymogstad]

How bad was the fuel smell after this? I know there should be none because it's a sealed unit but I'm curioushow dis you seal it to make it solid again? Just another piece od sheet metal?

[@deansouders6792]

There's 3 way todo anything. Right way wrong way and a way .this is a way not the right way just a way

[@lancecpldave]

You know they weld on gas tanks right. If it's full you can use a cut-off wheel no problem the sparks aren't that crazy. 😉

[@MINUTEDIYVIDEOS]

Haha yea I mean it’s not hydrogen 😅 def on the paranoid side 😂

[@NonPremiumID]

GM should had made access doors for fuel pump.

[@MINUTEDIYVIDEOS]

Considering how often the pumps fail, yes they really should have!

[@brucecarney4416]

Use nippers and you can re-use the piece you remove.

[@cincomorales]

Great video thank you mi I just subscribed

[@AlY-jv2ew]

First of all, Thank you, great vid. 1. I'd wash and lubricate the nightmare ring 2. GM, WHY do YOU do this antidesign?!! Why just not put simple tight ring that clicks. SIMPLIFY!!

[@benjaminjordan]

Thank you!

[@sleepsound9000]

What are the Measurements to location?

[@genemccormick7567]

What was the miles on your Astro when you replaced the pump ?

[@Deucealive75]

I got my 97 with 147K. My pump went out at 240K. Got one out of a pull a part Astro cheap. Pretty easy to pull the tank and replace it. Be sure to change the fuel filter every couple years to make life easier for the pump.

[@genemccormick3935]

@@Deucealive75 Was the pump you took out the original ( it should have been a Delco) ? My 1998 Safari has 160K or 99,000 miles. So far changing the relay and keeping the tank half full plus new filter has worked. Midas would install a new pump for $1000 or $750 U.S. Other shops want up to $1500 CAD.

[@Deucealive75]

@@genemccormick3935 Wow! That's a lot. Pretty sure mine was the original. I saved a ton by taking the chance on a junkyard fuel pump. I had to pull it at the yard. That would have been a good video. I used butchery and had the tank out in about 3 or 4 minutes. lol. I gave my son the van. It started to burn oil and he never kept up on checking or adding oil and locked up the engine at 247K. I bet it would still be on the road if he would have added the 1 quart a month it needed. I just got a pretty nice 05 with 101K miles. I need to replace the fuel filter soon.

[@Deucealive75]

@@genemccormick3935 Also. Those prices are way too high. If I had a lift, and correct parts on hand I could put a fuel pump in an Astro/Safari in 2 hours or less. Should be more like $300 (US) plus parts. On my back took longer. And I syphoned out 9 gallons to make the tank lighter.

[@hallhouse5098]

Just drop the tank, easy. Yes would be nice if they had an access cover with screws and a replaceable seal but that would make way too much sense. It’s all about manufacturing cost while totally ignoring the poor saps that have to work on them for a living.

[@russelltech7691]

I did mine this way. It's way easier than dropping the tank. And way faster.

[@kingofnewyork3]

Great 👍🏻 video but mines has a Shield 🛡on top of the gas tank yours didn’t.

[@MrMundaa]

ISTHE 94 THE SAME EXTENED VAN SAM LOCATION FUEL PUMP

[@edb8257]

Why am I always the guy with an astro this wont work because there is shield on top of the Fpump floor is cut thru and measurements are exact BUT THERE IS ANOTHER PLATE COVERING THE FUEL PUMP.

[@stevepanebianco5930]

what year is yours ? i have a 1998 and thinking about cutting a door as well,but not if there is a plate like yours

[@dinorahalmada670]

Chevrolet Silverado 4.3. Engine

[@malachigreenidge]

Just cut through my floor to find another plate as well No turning back now, gonna try and cut through this one too

[@possumtownpicker6551]

uhhh it works alright yet there is now a hole in your floorboard lol

[@doughtr721]

Here's a really cool idea, car manufactures engineering and designing vehicles that would be enjoyable to work on. they build perfect cars for a perfect world, but we don't live in a perfect world. they do at some point break down. why not make them friendly to work on? this is ridicules.

[@iplaypearldrums7935]

Nice silent movie....🤔🤔 No ghetto music 😜😜😜

[@charleswilson3933]

Use a grinder damn

[@josephpettus3718]

How the hell can you do this threw the body. This will not be an easy repair is why you didn't show that part.. People will be having tio drop the tank now to have the body rewelded. To seal the co2 from coming into the vehical this is not a safe method this is j it st to recover a part In a scrap yard .. Come on people it's two straps that hold this 13gallon tank in its not as hard as this cutting the floor out whe you have to remove tank to weld the hole buck up. I AM A 30 YEAR MASTER MACHANIC. THIS IS NOT SAFE TO DO WHEN YOU OPEN THE UNDER CARRAGE TO THE PASSENGER COMPARTMENT YOU HAVE A POISONOUS GAS ENTERING THE VEHICAL AND WELL CAN LEAD TO DEATH STROKE OR AND ACCIDENT WHEN YOU PASS OUT AND HIT SOMEONE HEAD ON... IT'S AN2 HR JOB WHEN YOU TAKE ONE OUT AND INSTALL PU P AND REINSTALL TANK IF YOU ARE HALF ASS EXPERIENCED.. if not don't attempt it.. This is an electrical device being installed in a submerged highly flammable yet explosive situation in side a tank. It would explode with the slights of a spark from an improperly wired electrical connection and should be installed by an experienced person. Be safe not dead. Take the time to remove the two straps and have a few pieces of wood on a couple bricks and them lossen the straps. Ifi rember correctly the rear strap is a itch to get to threw the frame but a few extentions and a swivel will allow access.

[@regarry10]

This is a "shade tree" repair and very unsafe, CO not CO2 may seep in and SIMPLY kill you. Low budget terrible repair!!!!

[@Deucealive75]

He just wanted to save on the huge cost of a tow. I pulled the tank on a rusty 97 Safari. Fairly easy.

[@garykentner7557]

This method screwed up the integrity of the floor. Its not difficult to Pull the filler neck and the straps. You really didnt save time unless you are going to leave the hole in the floor. if the fuel tank has lots of fuel in it the gas can be siphoned out the fuel fill pipe its only a hose clamp. I think this method created more work and you never did show a method to put back the sheet metal. I dont like this method its a short cut that creates more problems than its worth. I have 0ver 40 years of experience as a professional mechanic and I would not do this. Its really a simple job to do it the right way. I could see this being a desperate road side repair but thats it.

[@dsihacker01]

Every single astro that has gotten the pump fixed I've owned has had it done this way, instead of dropping the tank, I thought the same thing, I thought they were dumb, until me, and my buddy who does mechanic work for a living dropped a tank off a parts van... You learn quick at least!

[@Jamie-ju5zb]

Then it would be nice to see your video ,done the way you talking about. I have 86 rv/van. The parts are hard to find as well as videos to fix this vehicle

[@richardknottek6618]

No more difficult and time consuming than this job is, this technique is just dumb...

[@jayblue5310]

Slow your work down poor presentation

[@derrickwoods2803]

Terrible workmanship